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KAESER ESD 352 SFC, Technical Documentation Manual

The KAESER ESD 352 SFC is a high-quality industrial air compressor designed for efficiency and reliability. For comprehensive understanding and proper maintenance, make sure to download the Technical Documentation Manual for free from 88.208.23.73:8080. This manual will provide you with all the information needed to operate your compressor effectively.

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Tab. 1 Danger levels and their definitions (personal injury) ..................................................................

2

Tab. 2 Danger levels and their definition (damage to property) ............................................................

2

Tab. 3 User interface .............................................................................................................................

4

Tab. 4 Display data ................................................................................................................................

4

Tab. 5 Interfaces ....................................................................................................................................

5

Tab. 6 RFID ...........................................................................................................................................

5

Tab. 7 SC2IOM-1 ..................................................................................................................................

5

Tab. 8 SC2IOM-2 ..................................................................................................................................

6

Tab. 9 SC2IOM-3 ..................................................................................................................................

6

Tab. 10 Power supply specifications .......................................................................................................

6

Tab. 11 Cable lengths .............................................................................................................................

7

Tab. 12 Degree of protection, IOM ..........................................................................................................

7

Tab. 13 IOM dimensions .........................................................................................................................

7

Tab. 14 Pressure transducer ...................................................................................................................

7

Tab. 15 Resistance thermometer ............................................................................................................

7

Tab. 16 Keys ...........................................................................................................................................

11

Tab. 17 Indicators ....................................................................................................................................

12

Tab. 18 RFID sensor field ........................................................................................................................

13

Tab. 19 Reset check box status ..............................................................................................................

16

Tab. 20 Check box status ........................................................................................................................

16

Tab. 21 Menu structure ...........................................................................................................................

20

Tab. 22 Status menu ...............................................................................................................................

22

Tab. 23 Configuration menu ....................................................................................................................

23

Tab. 24 Pressure control menu ...............................................................................................................

24

Tab. 25 I/O periphery menu .....................................................................................................................

25

Tab. 26 Communication menu ................................................................................................................

26

Tab. 27 Profibus ......................................................................................................................................

27

Tab. 28 Modbus .......................................................................................................................................

27

Tab. 29 Modbus TCP ..............................................................................................................................

28

Tab. 30 DEVICENET ...............................................................................................................................

28

Tab. 31 PROFINET .................................................................................................................................

28

Tab. 32 Connections menu .....................................................................................................................

29

Tab. 33 Components menu .....................................................................................................................

29

Tab. 34 Power switching module – menu ................................................................................................

30

Tab. 35 Machine identification .................................................................................................................

35

Tab. 36 Remote control identification ......................................................................................................

35

Tab. 37 Machine identification .................................................................................................................

35

Tab. 38 Display language  .......................................................................................................................

37

Tab. 39 Date formats ...............................................................................................................................

44

Tab. 40 Time formats ..............................................................................................................................

44

Tab. 41 Units of pressure ........................................................................................................................

45

Tab. 42 Units of temperature ...................................................................................................................

46

Tab. 43 Display illumination .....................................................................................................................

46

Tab. 44 Arrow keys and functions ...........................................................................................................

52

Tab. 45 Compressor pressure parameters ..............................................................................................

59

Tab. 46 Setting limits for system setpoint pressure (* Cut-in pressure min) ............................................

61

Tab. 47 Pressure condition for LOAD  .....................................................................................................

61

Tab. 48 Pressure condition for IDLE  ......................................................................................................

61

Tab. 49 Example: Activated output ..........................................................................................................

62

Tab. 50 Settings for machine start and stop. ...........................................................................................

65

Tab. 51 Example of a machine ON/OFF timer program ..........................................................................

66

Tab. 52 Local operating mode (local mode) ............................................................................................

82

Tab. 53 Example of system pressure changeover switching points ........................................................

83

Tab. 54 Master control – overview ...........................................................................................................

87

List of Tables

9_9450 03USE

Service manual    Controller  
SIGMA CONTROL 2  SCREW FLUID 1.1.3

vii

Summary of Contents for ESD 352 SFC

Page 1: ...Compressor No ESD 2C Serial No 1205 Table of Contents 1 Dimensional drawing 2 Electrical diagram 3 Service manual compressor 4 Service manual Sigma Control 5 Spare Parts List 6 Performance test by hel...

Page 2: ...Project Florence12 L 00478 Order No 10357405 Technical Documentation Compressor Typ ESD 442 SFC 14 bar a ac Helium Compressor No ESD 2C Serial No 1205 1 Dimensional drawing...

Page 3: ...z Original Blatt Sprache Name Datum Ma stab Projektion nderungs Nr USE F R E I G E G E B E N Dimension and connection dim DRESSEL4 MALTER1 MALTER1 03 09 2013 30 08 2013 ESD 2C SFC K1 23 05 2013 1 von...

Page 4: ...Project Florence12 L 00478 Order No 10357405 Technical Documentation Compressor Typ ESD 442 SFC 14 bar a ac Helium Compressor No ESD 2C Serial No 1205 2 Electrical diagram...

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Page 36: ...Project Florence12 L 00478 Order No 10357405 Technical Documentation Compressor Typ ESD 442 SFC 14 bar a ac Helium Compressor No ESD 2C Serial No 1205 3 Service manual compressor...

Page 37: ...al Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E Manufacturer KAESER KOMPRESSOREN 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http ww...

Page 38: ...Original instructions KKW SESD 2 02 en 05 ESD_2C_10357405_10 000_00 KKW SSC 2 02 05 20130903 095638...

Page 39: ...2 15 Water cooling 11 2 15 1 Water cooling plate type heat exchanger 12 2 15 2 Water cooling Bundled pipe heat exchanger 13 3 Safety and Responsibility 3 1 Basic instructions 15 3 2 Specified use 15 3...

Page 40: ...xternal pressure transducer 40 6 7 Options 40 6 7 1 Anchoring the machine 40 6 7 2 Connecting the cooling water 41 7 Initial Start up 7 1 Ensuring safety 42 7 2 Instructions to be observed before comm...

Page 41: ...10 15 Replenishing the cooling oil 68 10 15 1 Venting the machine de pressurising 68 10 15 2 Topping up with cooling oil and trial run 69 10 16 Changing the cooling oil 70 10 17 Changing the oil filte...

Page 42: ...Contents iv Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 43: ...ooling oil collecting tank 58 Fig 22 Switching cabinet ventilation 59 Fig 23 Cleaning the cooler 60 Fig 24 Cooling air filter mat 61 Fig 25 Compressor motor maintenance 62 Fig 26 Checking the coupling...

Page 44: ...List of Illustrations vi Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 45: ...water temperature T 10K 13 Tab 23 Specification Heat exchanger Option K9 13 Tab 24 Cooling water quality 14 Tab 25 Inspection intervals according to Ordinance on Industrial Safety and Health 16 Tab 2...

Page 46: ...List of Tables viii Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 47: ...the data from the nameplate when ordering documents 1 3 Copyright This service manual is copyright protected Queries regarding use or duplication of the documenta tion should be referred to KAESER Co...

Page 48: ...ere 2 Always read and comply with warning instructions 1 4 2 Potential damage warnings Contrary to the warnings shown above damage warnings do not indicate a potential personal in jury Warning notices...

Page 49: ...ne option only are marked with an option code e g H1 indicates that this section applies only to machines with screw in machine feet Option codes used in this service manual are explained in chapter 2...

Page 50: ...abs Ambient temperature Tab 3 Nameplate 2 2 Options The table contains a list of possible options Enter options here as a reference Option Option code Available SIGMA CONTROL 2 C3 Adjustable machine...

Page 51: ...ermissible ambient tem perature C 3 45 Permissible cooling air temperature C 3 45 Permissible gas intake temperature K 276 318 Humidity of the intake gas absolutely dry Higher altitudes are permissibl...

Page 52: ...essure 5 Pressure relief valve acti vating pressure bar abs 16 0 Any other operating conditions are excluded and require consulting with the manufacturer Tab 9 Ambient conditions 2 8 Mass flow rate Fi...

Page 53: ...ge 2 8 1 Mass flow rate m g s at maximum working pressure of 14 0 bar abs p1 bar abs ESD 442 m min m max 14 0 31 1 79 5 at 1 05 bar abs suction pressure 298 K inlet temperature Tab 11 Mass flow rate 2...

Page 54: ...d speed min 1 1792 Protection rating IP 55 Motor bearing re greas ing interval h 1500 Grease requirement each bearing g h operating hours Copy the data from the motor nameplate into the table Tab 14 C...

Page 55: ...ational Electric Code NEC NEC 670 particularly NFPA 79 edition 2007 section 4 3 The machine requires a symmetrical three phase power supply In a symmetrical three phase supply the phase displacement a...

Page 56: ...ower supply connection 2 14 Power supply specifications The following multi strand copper core wires are given according to 2012 NEC 310 15 Ta ble 310 16 for 40 C ambient temperature If other local co...

Page 57: ...mes due to corrosion calcification and contamination It is imperative that measures for cooling water treatment and filtration are implemented and performed KAESER can provide the names of companies s...

Page 58: ...m permissible in let temperature C 40 Flow rate m3 h 22 7 Pressure drop bar 2 0 Tab 19 Cooling water temperature T 10K Heat exchanger specification ESD 442 Material 1 4401 Braze Copper Cu Maximum work...

Page 59: ...oling Bundled pipe heat exchanger The primary winding of the heat exchanger is connected to the machine The specifications refer to the secondary side of the heat exchanger 2 15 2 1 Design data Coolin...

Page 60: ...0 250 Dissolved iron Fe mg l 0 5 0 2 Sulphate SO4 mg l 300 300 HCO3 SO4 ratio 1 1 Electrical conductivity S cm 10 2500 10 2500 Ammonia NH4 mg l 2 1 Manganese Mn dissolved mg l 0 1 0 1 Glycol 20 40 Sol...

Page 61: ...s listed in this service manual Operate the machine only within its performance limits and under the permitted ambient condi tions see chapter 2 3 3 Improper use Improper usage can cause damage to pro...

Page 62: ...dequate training in and authorization for the safe installation and maintenance of this machine Ensure that personnel entrusted with operation installation and maintenance are qualified and authorised...

Page 63: ...m direct or indirect contact Before starting any work on electrical equipment Switch off and lock out the power supply isolator and check that no voltage is present Switch off any external power sourc...

Page 64: ...ite because of sparks or heat Noise The enclosure absorbs the machine noise to a tolerable level This function will be effective only if the enclosure is closed Operate the machine only with intact so...

Page 65: ...duct that will help in handling the machine safely is given here Personal protective equipment When working on the machine you may be exposed to dangers that can result in accidents with severe advers...

Page 66: ...ature and humidity Clean inlet gas with no damaging contaminants Damaging contaminants are for instance explosive or chemically instable gases and vapours acid or base forming substances such as ammon...

Page 67: ...s 3 5 3 Organisational Measures Designate personnel and their responsibilities Give clear instructions on reporting faults and damage to the machine Give instructions on fire reporting and fire fighti...

Page 68: ...evice and check that no volt age is present 9 Machine starts automatically Severe injury could result from rotating components electrical voltage and air pres sure Isolate from the power supply and lo...

Page 69: ...an result from loud noise and or oil mist when the safety relief valve opens Wear ear protection and protective clothing Close all access doors and cover panels 27 Risk of electric shock If the interr...

Page 70: ...er running water Seek medical help if irritation persists Skin contact Cooling oil may irritate after prolonged contact Wash thoroughly with skin cleaner then with soap and water Contaminated clothing...

Page 71: ...the use of genuine KAESER spare parts and operating materials Obtain confirmation from KAESER that your specific operating conditions are suitable 3 10 Environment protection The operation of this mac...

Page 72: ...Walking on standing or sitting on As resting place or storage of any kind of load Safe and reliable operation is only assured with the enclosure closed Access doors are hinged to swing open and remova...

Page 73: ...optimum cooling oil temperature Compressed gas freed of cooling oil in the oil separator tank 7 flows through the minimum pres sure check valve 2 into the gas cooler 9 The minimum pressure check valv...

Page 74: ...ng 4 5 2 Option H1 Machine mountings These mountings allow the machine to be anchored firmly to the floor Fig 6 Machine mountings 4 5 3 Option K3 Cooling air filter mat The mat filters the cooling air...

Page 75: ...very and the absolute working pressure These changes in speed match the gas delivery to the gas consumption and keep system pressure as constant and as close as possible to the SETPOINT pressure This...

Page 76: ...8 UP Scrolls up the menu options Increases a parameter value 9 Events and information Operating mode Displays the event memory 10 Acknowledgement Acknowledges alarms and warning messages If permissib...

Page 77: ...edged 18 Controller voltage Lights green when the power supply is switched on 19 LOAD Lights green when the compressor is running under LOAD 20 IDLE Lights green when the compressor is running in IDLE...

Page 78: ...em have been provided with the machine Typical application Users log on to the machine no manual input of the password required Fig 10 RFID sensor field Item Description Function 24 RFID RFID sensor f...

Page 79: ...e display can be read and work carried out comfortably and safely Keep suitable fire extinguishing agents ready for use Ensure that required ambient conditions are maintained Required ambient conditio...

Page 80: ...t all intake and exhaust apertures of the enclosure remain opened 5 If installed outdoors the machine must be protected from frost direct sunlight dust and rain 5 2 2 Ensuring the machine room ventila...

Page 81: ...the design of flaps or shutters 5 3 Operating the machine in a compressed gas network High pressure side If the compressor is integrated in a gas network the pressure side may not exceed 17 bar a Init...

Page 82: ...filter contamination a pressure differential monitoring installed by the user shall trigger an alarm or switch off the machine in time before the system falls below permissible intake pressure Oil re...

Page 83: ...Switch off and lock out the power supply isolating device and verify the absence of voltage Before starting work on the frequency converter or intermediate circuit capacitors wait at least 5 minutes C...

Page 84: ...rrier and the manufacturer in writing of any damage without delay 6 3 Checking the tightness For transport and short term storage the machine is filled in the factory with gas with an overpres sure of...

Page 85: ...the overcurrent protection cut out to ensure that the time it takes to disconnect in re sponse to a fault is within the permitted limit 4 Select supply cable conductor diameters and fusing in accordan...

Page 86: ...g transformer in the control cabinet 2 Connect the power supply for the isolating amplifier 3 Make the connection between the output of the isolating amplifier and the analog input of the frequency co...

Page 87: ...ecting the cooling water A Cooling water outlet B Cooling water inlet 10 Shut off valve 12 Connection port with plug 17 Pressure relief valve 1 The user is to provide the following fittings Dirt traps...

Page 88: ...ns Switch off and lock out the power supply isolating device and verify the absence of voltage Before starting work on the frequency converter or intermediate circuit capacitors wait at least 5 minute...

Page 89: ...han Remedy 3 months Manually fill the airend with cooling oil 12 months Change the oil filter Change the oil separator cartridge Change the cooling oil Have the motor bearings checked by an authorised...

Page 90: ...nverter parameters are preset Adjustment of parameters to suit operating condi tions on site is done by trained and authorised personnel Changes to the factory settings may influence the whole machine...

Page 91: ...m the inlet valve 2 Pour the stipulated amount of cooling oil into the airend and replace the filler plug 3 See the LINDE operating manual for cleaning instructions Fig 15 Coupling 1 Airend 2 Coupling...

Page 92: ...Evacuation 1 Close the user s shut off valves at the inlet and outlet ends 2 Evacuate the machine to a minimum vacuum of 5 mbar using the hose couplings of the evac uation connections see chapter 13 1...

Page 93: ...he direction of rotation of the fan with the arrow on the motor casing 7 11 Setting the display language The controller can display text messages in several languages You can set the language for text...

Page 94: ...he green Control voltage LED is lit continuously 2 Press the ON key The green Machine ON LED is lit continuously If a power failure occurs the machine is not prevented from re starting automatically w...

Page 95: ...actuation The compressor s pressure system is vented and the machine is prevented from automatically re starting Switching on Precondition The fault has been rectified 1 Turn the EMERGENCY STOP device...

Page 96: ...starting device in the remote control centre as follows Remote control danger of unexpected starting Before starting make sure that no one is working on the machine and that it can be safely started...

Page 97: ...omatically display operation messages informing you about the current opera tional state of the machine Operating messages are identified with the letter O Further information Detailed information can...

Page 98: ...nformation A list of possible alarm messages occurring during operation can be found in the service manual SIGMA CONTROL 2 Warning message If maintenance work is to be carried out or if the warning is...

Page 99: ...g partially Contact KAESERservice Venting valve not closing Contact KAESERservice Pressure system leaking Check pipework and connec tions for leaks and tighten any loose fittings Gas demand exceeds th...

Page 100: ...oling oil consumption too high Unsuitable oil is being used Use recommended cooling oil Oil separator cartridge split Change the oil separator car tridge Oil level in the oil separator tank too high D...

Page 101: ...Touching voltage carrying components can result in electric shocks burns or death Dangerous voltages persist in the frequency converter and intermediate circuit capacitors for some time after power i...

Page 102: ...er 3 4 2 Details of dangers and their avoidance are found in chapter 3 5 10 2 Linde regulations Linde regulations have priority and should be observed in all maintenance and service work 10 3 Followin...

Page 103: ...erval Maintenance task See chapter weekly Check the cooling oil level 10 13 Check the oil collecting tank 10 4 Control cabinet Check the filter mat 10 5 Up to 1 000 h Clean the cooler 10 6 Check the c...

Page 104: ...0 h Change the coupling Check the airend Compressor drive motor Replace the motor bearings h operating hours Tab 39 Regular service tasks 10 4 Check the oil collecting tank A certain amount of oil dif...

Page 105: ...nd take out the filter mat 2 Beat the mat or use a vacuum cleaner to remove loose dirt If necessary wash with lukewarm water and household detergent 3 Replace the filter mat if cleaning is not possibl...

Page 106: ...Have stubborn clogging removed by an authorized KAESER Service Technician Check the cooler for leaks Carry out visual inspection Did cooling oil escape Is a cooler leaking Have the defective cooler r...

Page 107: ...chnician should clean the cooler when the airend discharge temperature is 10 C above the annual average Check the gas and oil cooler for leaks 10 8 Option K3 Cleaning or Renewing the Cooling Air Filte...

Page 108: ...they latch 10 9 Motor maintenance Use only the high temperature grease ESSO UNIREX N3 for the motor bearings Bearing damages caused by the use of other brands of grease are excluded from the warranty...

Page 109: ...running 1 Clean the nipple 2 with a cloth before greasing 2 Grease both bearings with a grease gun 3 Reset the maintenance interval counter Fan motor Have the fan motor bearings checked by a KAESER S...

Page 110: ...Has the coupling cracks or colour changes Have a damaged coupling changed by an authorised KAESER Service Technician 10 11 Checking the pressure relief valve In order to check the pressure relief valv...

Page 111: ...ssure relief valve blows off or working pressure exceeds the activating pressure of the pressure relief valve by nearly 1 bar 7 If necessary vent the machine and replace the defective pressure relief...

Page 112: ...cooler The machine must be isolated from the gas network and completely vented before undertak ing any work on the pressure system Material The maintenance hose with hose coupling and shut off valve n...

Page 113: ...h the shut off valve closed insert the male hose fitting 6 into the hose coupling 3 Slowly open the shut off valve 7 to release pressure Disconnect the male hose fitting 6 and close the shut off valve...

Page 114: ...Oil filler port with plug 5 Cooling oil level indicator 6 Male hose fitting 7 Shut off valve A Shut off valve open B Shut off valve closed 8 Maintenance hose 1 Vent the machine as described in section...

Page 115: ...he minimum pres sure 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 pressure 3 Disconnect the male h...

Page 116: ...to expel the oil This compressed gas can be taken either from the compressor itself or from an external source An external source of compressed gas is necessary in the following cases The machine is...

Page 117: ...rify the absence of any voltage 4 Wait at least 2 minutes to allow the oil to flow back to the separator tank The power supply isolating device is switched off the device is locked off the absence of...

Page 118: ...6 Plug in nozzle 7 Shut off valve 1 Have an oil receptacle ready 2 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 2 3 Place the other end of the maintenance hose...

Page 119: ...small amount of cooling oil may flow back into the oil cooler and oil separator tank as a result of turning the coupling Remove this by repeating the steps for draining oil from the separator tank and...

Page 120: ...ecting device is switched off The disconnecting device is locked off A check has been made that no voltage is present The machine is fully vented the pressure gauge on the oil separator tank reads 0 b...

Page 121: ...sary 5 Switch off the machine and check visually for leaks 10 18 Changing the oil separator cartridge The oil separator cartridge cannot be cleaned The life of the oil separator cartridge is influence...

Page 122: ...ridge 1 Screw fitting 2 Dirt trap 3 Screw fitting 4 Air pipe 5 Fixing screw 6 Clamping nut 7 Gasket 8 Oil separator cartridge 9 Minimum pressure check valve 1 WARNING Compressed gas Compressed gas and...

Page 123: ...trap 2 12 Secure the air pipe 4 with a new self locking nut Follow the instructions in chapter 10 19 concerning flexible pipe connections 13 Replace and tighten all fittings Dispose of parts and mate...

Page 124: ...clean and undamaged 1 Slide the seal holder 2 and gasket 3 over the pipe 1 2 Slide the pipe end 1 into the bush 4 without pretension 3 Slide the gasket 3 with seal holder 2 up the sealing face of the...

Page 125: ...ice work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 41 Logged maintenance tasks 10 Maintenance 10 20 Documenting maintenance and service work ESD_2C_103574...

Page 126: ...e spares or operating fluids materials Use only original KAESER parts and operating fluids materials Have an authorised KAESER Service Technician carry out regular maintenance Machine Name Quantity Nu...

Page 127: ...ts and higher compressed gas availability 11 4 Service Addresses Addresses of KAESER agents are given at the end of this manual 11 Spares Operating Materials Service 11 4 Service Addresses ESD_2C_1035...

Page 128: ...ine 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 mechanical damage Other measures...

Page 129: ...ort the machine in freezing tempera tures Precondition Transport only using a forklift truck or lifting gear and only by personnel trained in the safe trans portation of loads Make sure the danger are...

Page 130: ...ear Do not attach the lifting gear to any of the machine components 2 Use the lifting gear correctly and lift the machine carefully 12 5 Disposal When disposing of a machine drain out all liquids and...

Page 131: ...Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA...

Page 132: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 86 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 133: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 87...

Page 134: ...13 2 Dimensional drawing 13 Annex 13 2 Dimensional drawing 88 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 135: ...SE F R E I G E G E B E N Dimension and connection dim DRESSEL4 MALTER1 MALTER1 03 09 2013 30 08 2013 ESD 2C SFC K1 23 05 2013 1 von 1 Dokument TZM 10248151 USE 00 A2 Stand 12 11 2012 10248151 D 00 4 x...

Page 136: ...13 3 Electrical Diagram 13 Annex 13 3 Electrical Diagram 90 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 137: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 91...

Page 138: ...13 Annex 13 3 Electrical Diagram 92 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 139: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 93...

Page 140: ...13 Annex 13 3 Electrical Diagram 94 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 141: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 95...

Page 142: ...13 Annex 13 3 Electrical Diagram 96 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 143: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 97...

Page 144: ...13 Annex 13 3 Electrical Diagram 98 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 145: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 99...

Page 146: ...13 Annex 13 3 Electrical Diagram 100 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 147: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 101...

Page 148: ...13 Annex 13 3 Electrical Diagram 102 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 149: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 103...

Page 150: ...13 Annex 13 3 Electrical Diagram 104 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 151: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 105...

Page 152: ...13 Annex 13 3 Electrical Diagram 106 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 153: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 107...

Page 154: ...13 Annex 13 3 Electrical Diagram 108 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 155: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 109...

Page 156: ...13 Annex 13 3 Electrical Diagram 110 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 157: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 111...

Page 158: ...13 Annex 13 3 Electrical Diagram 112 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 159: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 113...

Page 160: ...13 Annex 13 3 Electrical Diagram 114 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 161: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 115...

Page 162: ...13 Annex 13 3 Electrical Diagram 116 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 163: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 117...

Page 164: ...13 Annex 13 3 Electrical Diagram 118 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 165: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 119...

Page 166: ...13 Annex 13 3 Electrical Diagram 120 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 167: ...13 Annex 13 3 Electrical Diagram ESD_2C_10357405_10 LIN_00 E Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 121...

Page 168: ...13 Annex 13 3 Electrical Diagram 122 Service Manual Screw Compressor ESD 442 14 bar abs SFC SIGMA CONTROL 2 ESD_2C_10357405_10 LIN_00 E...

Page 169: ...Project Florence12 L 00478 Order No 10357405 Technical Documentation Compressor Typ ESD 442 SFC 14 bar a ac Helium Compressor No ESD 2C Serial No 1205 4 Service manual Sigma Control...

Page 170: ...Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 1 3 9_9450 03USE Manufacturer KAESER KOMPRESSOREN 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com...

Page 171: ...KKW SSC 2 03 en 01 BA SIGMA CONTROL FLUID KKW SSC 2 03 01 20130805 113302...

Page 172: ...uick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 1 3 9_9450 03 USE Manufacturer KAESER KOMPRESSOREN 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com...

Page 173: ......

Page 174: ...Outputting important operational states of the machine 14 10 Resetting maintenance interval counters 15 11 Safety relief valve checking 17 12 Checking the temperature sensor and overheating shutdown f...

Page 175: ...Contents ii Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1 1 3 9_9450 03 USE...

Page 176: ...safe operation are found in subsequent chapters Setting and other work on the machine may only be carried out by the following persons persons trained on the machine controller and persons instructed...

Page 177: ...y At the same time press the UP or DOWN key Precondition The display shows the operating mode 1 Press Enter The main menu is displayed 2 Press and hold the Information key 89 psi 08 15 17 6 F Main men...

Page 178: ...xxxxx Submenu 2 xxxxxxxxxx Submenu 3 xxxxxxxxxx Submenu 4 xxxxxxxxxx Submenu 5 xxxxxxxxxx Submenu 3 Use the Enter key to switch to setting mode The currently set language flashes 4 Move to the require...

Page 179: ...r of the Equipment Card is also the user name The user name is required for a manual log on without Equipment Card Fig 1 KAESER Equipment Card 1 KAESER Equipment Card 2 Number of the KAESER Equipment...

Page 180: ...name and access level are displayed 2 Press Enter to confirm the log on The operating mode is displayed Result You are logged on Further information See chapter 7 2 6 for a manual log on to the contr...

Page 181: ...Press Enter to switch into setting mode The current value flashes 4 Use UP or DOWN to adjust the setting for the switching point pA 5 Press Enter to accept the setting 6 Press the Right key once 7 Pre...

Page 182: ...e line 02 n a 00 00 off Enter switching point 02 03 n a 00 00 off Enter switching point 03 Entering switching points 1 Press Enter to switch into setting mode The n a column flashes in the active line...

Page 183: ...e compressor ON compressor OFF actions are set for all switching points Activating the clock key 1 Use UP key to change to line Key clock 2 Press Enter to switch into setting mode The check box flashe...

Page 184: ...ogram Further information See chapter 7 5 for configuration of starting and stopping the machine See chapter 7 8 2 for configuration of load changeover based on a clock program 6 Activating the clock...

Page 185: ...ion Password level 2 is activated The display shows the operating mode Activating the Remote control key in the Compressor ON menu 1 Press Enter The main menu is displayed 2 Select Configuration Compr...

Page 186: ...ontrol menu Precondition Password level 2 is activated The display shows the operating mode 1 Press Enter The main menu is displayed 2 Select Configuration Pressure control Load control 3 Press UP rep...

Page 187: ...eatedly to return to the main menu 8 Press the Remote control key to enable remote mode Proceed in the same manner to deactivate the Remote control key Further information See chapter 7 5 for configur...

Page 188: ...e adjusted 1 Venting period 3 DUAL 4 QUADRO 3 Press Enter to switch into setting mode The display for DUAL control mode flashes 89 psi 08 15 17 6 F 5 3 Control mode Current menu Local mode QUADRO Acti...

Page 189: ...Controller on line is displayed as being active 3 Select the required message with the UP or DOWN keys 89 psi 08 15 17 6 F 5 7 1 DO functions Menu Controller on Active line DOR 1 05 Logic DOT 1 02 Lo...

Page 190: ...9 psi 08 15 17 6 F 4 Maintenance Menu Oil filter 6000 h 0005 h Reset Active line maintenance interval remaining service life Oil separator 6000 h 3000 h Reset 6 Use UP or DOWN to activate the Reset ch...

Page 191: ...deactivated Oil separator 6000 h 3000 h Reset Further information See chapter 8 9 for setting the maintenance intervals See chapter 10 for the maintenance of the controller 10 Resetting maintenance in...

Page 192: ...elief valve from the machine s nameplate 2 Press the OFF key to shut down the machine 3 Close the user s shut off valve between the machine and the air distribution network 4 Log on to SIGMA CONTROL 2...

Page 193: ...heck 8 If the internal pressure pi increases to more than 10 above the correct opening pressure of the safety relief valve shut down the machine with the OFF key and replace the safety relief valve If...

Page 194: ...st measured value as internal pressure Activate the check box for reset in order to reset the stored value Activate the check box Further information See chapter 8 10 to test the safety relief valve 1...

Page 195: ...est mode Overview Shut down the machine and allow to cool down slightly Performing the test Correct conclusion of the test Resetting Performing the test Precondition Machine has cooled down approximat...

Page 196: ...act KAESER Service as soon as possible Correct conclusion of the test 1 Press Enter to switch into setting mode The check box in the active line flashes 2 Use the DOWN key to deactivate the check box...

Page 197: ...in READY operating mode 0006 O Idle The machine is switched on and in IDLE operating mode 0007 O On load The machine is switched on and in LOAD operating mode 0008 O off The machine is switched off T...

Page 198: ...r 50 The internal voltage monitoring reports low voltage fault IOSlot2 0202 O IOSlot3 Undervoltage error 50 The internal voltage monitoring reports low voltage fault IOSlot3 0203 O IOSlot4 Undervoltag...

Page 199: ...Undervoltage error 50 The internal voltage monitoring reports low voltage fault IOSlot6 Tab 4 Operational messages 13 Interpreting operation messages 24 Quick user guide Controller SIGMA CONTROL 2 SC...

Page 200: ...the letter D They provide information on the status of the controller the connected input and output modules and support the KAESER service in troubleshooting 14 Interpreting diagnostic messages 9_94...

Page 201: ...n 0005 A Oil separator Temperature Maximum air temperature at the oil separator tank outlet is exceeded Check the line to the trip relay 0007 A Power supply monitor Fault in main power supply Have the...

Page 202: ...ressure pi 0021 A Refrigeration dryer T Refrigeration dryer Compressed air temperature too low Contact an author ized KAESER service representa tive 0022 A Oil separator p Oil separator cartridge clog...

Page 203: ...air The working pressure does not rise above 50 psi within a default period Check the machine for leaks Check coupling V belts 0045 A Compressor T Thermostatic valve defective Contact an author ized...

Page 204: ...ing oil level 0062 A Refrigeration dryer p Refrigerated dryer Pressure too high in the re frigerant circuit Safety pressure switch trip ped Clean the refriger ant condenser Check the fan mo tor Mainta...

Page 205: ...rator car tridge 0102 A Oil air cooler fan Overcurrent Overload shut down of the first fan motor Investigate cause of shut down Reset the overload relay 0200 A Compressor motor USS alarm Frequency con...

Page 206: ...or FC Motor overload alarm Frequency converter fault Contact an author ized KAESER service representa tive Tab 5 Fault messages and remedies 15 Interpreting fault messages 9_9450 03 USE Quick user gui...

Page 207: ...g oil level Replace the oil filter cartridge Ensure adequate ventilation Keep surrounding tempera ture within recommended lim its 0011 W Oil filter p Increased pressure dif ferential of the oil filter...

Page 208: ...rvice 0035 W PD temperature Compressed air dis charge temperature too high Clean the cooler Check the cooling oil level 0036 W Motor starts h The permissible number of motor starts was ex ceeded in th...

Page 209: ...the read ing on the oil separator tank pressure gauge 0048 W Bearing lube h Re grease the motor bearings Maintenance interval has elapsed Re grease the motor bear ings 0049 W Annual maintenance Last...

Page 210: ...igerant liquefier Clean the cooler Install an extractor fan 0071 W Oil level Cooling oil level too low Replenish the cooling oil 0072 W RD condensate drain Refrigerated dryer The condensate drain is d...

Page 211: ...0003 Y Filesystem Read Write failure System error Contact an authorized KAESER service representative 0004 Y CPU load too high System error Contact an authorized KAESER service representative 0005 Y...

Page 212: ...ge of the RFID Equipment Cards 17 4 5 Checking the machine status with KAESER CONNECT 17 4 6 Menus overview 18 4 6 1 Operating mode 18 4 6 2 Menu structure 19 4 7 Operating modes and control modes 30...

Page 213: ...usting the idle time of DUAL mode 76 7 6 3 Adjusting the minimum running and unloaded period in QUADRO control mode 76 7 7 Activating the settings for the refrigerated dryer 77 7 7 1 Setting the CLOCK...

Page 214: ...8 4 1 Selecting the Status menu 144 8 5 Displaying the current operating mode 145 8 6 Adjusting working pressure 146 8 7 Displaying analog data 147 8 8 Displaying operating data 148 8 8 1 Interpreting...

Page 215: ...Contents iv Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 1 3 9_9450 03USE...

Page 216: ...a new user 56 Fig 20 Settings 57 Fig 21 Data backup 58 Fig 22 Header 59 Fig 23 Pressure rise in frequency controlled SFC machines 63 Fig 24 Profibus plug wiring 89 Fig 25 Electrical diagram example wi...

Page 217: ...List of Illustrations vi Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 1 3 9_9450 03USE...

Page 218: ...EVICENET 28 Tab 31 PROFINET 28 Tab 32 Connections menu 29 Tab 33 Components menu 29 Tab 34 Power switching module menu 30 Tab 35 Machine identification 35 Tab 36 Remote control identification 35 Tab 3...

Page 219: ...24 Tab 62 Logic 132 Tab 63 Transmission of sensor value 136 Tab 64 Checklist of installation conditions 138 Tab 65 Information of a message 143 Tab 66 Message type and status abbreviations 143 Tab 67...

Page 220: ...by pointing your browser to the COPYING file in the root directory of SIGMA CONTROL 2 URL http Hostname SIGMA CONTROL 2 COPYING The licenses can be also found under this address http www gnu org lice...

Page 221: ...lethal or severe in jury will occur The measures required to protect yourself from danger are shown here Warning notes referring to a sub section or the subsequent action are integrated into the proc...

Page 222: ...y to carry out the task The conditions relevant to safety shown here will help you to avoid dangerous situations This symbol denotes lists of actions comprising one stage of a task Operating instructi...

Page 223: ...Number of membrane keys 13 Number of LEDs 9 Degree of protection control cabinet exterior IP 54 Degree of protection control cabinet interior IP 20 Voltage V 24 Current A 0 3 Voltage source Input out...

Page 224: ...ut output modules with different amounts of inputs and out puts The actually available number of input output modules depends on the machine type and the avail able options Refer to the machine s wiri...

Page 225: ...OM 2 IOM 3 Input Output Input output module 3 Internal into the control cabinet available in parallel on both sides External into the compres sor interior Digital input DI 24 VDC 6 2 Analog input curr...

Page 226: ...tection Feature Value Degree of protection within the machine IP 54 Degree of protection within the control cabinet IP 20 Tab 19 Degree of protection IOM 2 1 2 4 Input output modules dimensions Featur...

Page 227: ...Feature Value Connection Twin cable Tab 22 Resistance thermometer 2 Technical Data 2 1 SIGMA CONTROL 2 Controller 8 Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1 1 3 9_9450 03USE...

Page 228: ...ies with Industry Canada licence exempt RSS standard s Operation is subject to the following two conditions this device may not cause interference and this device must accept any interference includin...

Page 229: ...dentification with the KAESER RFID Equipment Card Slot for customer interface optional communications module SD card slot for SD SDHC cards Manual loading of updates with an SC card reading or recordi...

Page 230: ...alarms that may lead to damage to the machine e g high current high pressure or high temperature 4 2 Operating panel Keys Fig 4 Keys overview Position Name Function 1 OFF Switches the machine off 2 ON...

Page 231: ...e control Switches the remote control on and off 13 Timer control Switches the timer control on and off Tab 23 Keys Indicators Fig 5 Indicators overview Position Name Function 14 Display Graphic displ...

Page 232: ...he abbreviation for Radio Frequency IDentification and enables the identification of per sons or objects Placing a suitable transponder in front of the RFID sensor field of the controller will automat...

Page 233: ...back ground The following parameters are displayed permanently on the title bar Working pressure Time Airend discharge temperature Lines 3 and 5 Operational state Depending on the settings either the...

Page 234: ...te menus in the menu structure by the number preced ing their designation The menu structure is explained in chapter 4 6 2 Active line The active line is always shown as white text on a dark backgroun...

Page 235: ...ess again Enter to save the settings The display line no longer flashes and the key is activated Proceed correspondingly to deactivate a key Check box Status activated deactivated Tab 27 Check box sta...

Page 236: ...and thus check the energy efficiency of the machine KAESER CONNECT does not require additional and expensive special software applications KAESER CONNECT selectively visualizes the current sta tus of...

Page 237: ...ease note the designations in the menu s header The designations cover user friendly func tions such as Activating write mode You can switch from read mode to write mode to create a new user account f...

Page 238: ...n 500 h The following parameters are displayed Operating mode of the machine Information on the LOAD IDLE keys Remote control or Timer Value for the system setpoint pressure pA Number of operating hou...

Page 239: ...enu 2 Performance data Display of the following measured data System pressure pNloc ADT airend discharge temperature Increased speed ADT p Oil separator Starting temperature Temperature MCS Main Contr...

Page 240: ...int 02 Switching point 03 Switching point 04 Switching point 05 Switching point 06 Switching point 07 Switching point 08 Switching point 09 Switching point 10 7 User Name Password Current access level...

Page 241: ...arts below mini mum temperature Last load run Last idle run Last motor OFF 1 3 Current pressure control SIGMA CONTROL 2 Cut out pressure Actual system pressure 1 4 Current operating mode Compressor ON...

Page 242: ...KAESER Part number Serial number Controller manufacturer Part number Serial number Date of manufacture Compressor Equipment number Part number Serial number IO modules First IOM 5 2 Pressure control...

Page 243: ...32 I O periphery menu 5 8 Timer ON OFF DOR 1 03 5 9 Refrigeration dryer Control mode Compressor standby Compressor clock FK FB off Temperature high Temperature low Activate fault mode Tab 30 Configur...

Page 244: ...unction submenu 5 7 1 DO functions Controller on ON Motor running IDLE LOAD Group fault Group warning Remote operation Timer active EMERGENCY OFF Timer contact enter timing program 5 7 2 Analogue valu...

Page 245: ...P configuration IP address Subnet mask Gateway DNS Server 1 DNS Server 2 Network restart Connections SIGMA CONTROL 2 Control technology Restart Time out Cycle time For details of the Connections menu...

Page 246: ...nu 4 6 2 4 COM module menu Navigation Function 8 2 Com Module Profibus Status Start Com module Slave number Reset Bus fault Start time Time out Tab 34 Profibus Navigation Function 8 2 Com Module Modbu...

Page 247: ...DeviceNet Status Start Com module Slave number Reset Bus fault Start time Time out Tab 37 DEVICENET Navigation Function 8 2 Com Module Profinet Status COM module start Reset Bus fault Start time Time...

Page 248: ...onnections menu 4 6 2 6 Menu Components Navigation Function submenu 10 1 Compressor motor Power switching Star delta start Direct start High voltage cell SFC USS Softstart Mains contactor hysteresis t...

Page 249: ...contactor SFC USS Service mode Main contactor Softstart Ready Engine running Run up over Start Reset Main contactor Tab 41 Power switching module menu 4 7 Operating modes and control modes 4 7 1 Opera...

Page 250: ...etween its various opera tional states in order to compensate for air being drawn off by consumers and to maintain the sys tem pressure between the set minimum and maximum values The control mode also...

Page 251: ...rature The lower the drive motor temperature the sooner and therefore more often and longer it is stopped MODULATING control The MODULATING control is an additional mechanical regulation It continuous...

Page 252: ...converter runs the motor up to a speed at which air delivery matches the air de mand The inlet valve opens and the machine delivers compressed air The frequency converter varies the speed of the drive...

Page 253: ...end the machine into which the controller is installed UV radiation Direct sunlight UV radiation can destroy the display screen Do not allow the display screen to be subjected to direct sunlight See t...

Page 254: ...tched off before commencing any work on the machine Tab 42 Machine identification Label the starting device in the remote control center as follows suggestions Remote control danger of unexpected star...

Page 255: ...ent 7 13 Linking to an external pressure transducer 7 14 Commissioning the machine 7 2 Configuring the controller All controller settings are explained in detail in the following sections The most com...

Page 256: ...ian Italian Norwegian Spanish Bulgarian Finnish Japanese Polish Spanish South America Chinese French Korean Portuguese Czech Danish French Canada Croatian Romanian Turkish German Greek Latvian Russian...

Page 257: ...the SIGMA CONTROL 2 with the Equipment Card Use the Equipment Card to quickly and easily check the advanced access rights to the SIGMA CONTROL 2 Advanced access rights let you Read additional data Ch...

Page 258: ...the User menu The Name line is displayed as the active line 89 psi 08 15 17 6 F 7 User Menu Name E00019895 Active line display of your Equipment Card s num ber Password Logout Current access level 2...

Page 259: ...on without your Equipment Card 9 Press Enter to accept the setting 7 2 6 Controlling access to the SIGMA CONTROL 2 via manual input In the event that your Equipment Card is damaged or lost you must ma...

Page 260: ...ine user name Password Login Current access level 0 Display access level 0 8 Press DOWN once The Password line is displayed as the active line 9 Press Enter to switch into setting mode A column with a...

Page 261: ...This password is also generated at the SIGMA CONTROL 2 Entering the password is necessary to Log on to KAESER CONNECT Activate the write mode in the User accounts menu Proceed as described for Genera...

Page 262: ...ettings 12 Press Esc repeatedly to return to the Main Menu Checking setting the date Precondition Password level 2 is activated the Configuration General menu is selected see 7 2 1 1 Press the DOWN ke...

Page 263: ...key repeatedly until Date format is displayed as the active line 89 psi 08 15 176 F 5 1 General Menu Date time 13 04 11 08 15 37 Europe Berlin Date format DD MM YY Current date format Time format hh m...

Page 264: ...Setting the pressure display units Select your preferred display of the pressure unit Format Example bar 5 5 bar hPa 5523 hPa MPa 0 55 MPa psi 80 psi at 5 6 at Hg 162 9 Hg Tab 48 Units of pressure Pre...

Page 265: ...re Display lighting 2 Press Enter to switch into setting mode The C parameter flashes 3 Change the unit with the DOWN or UP keys 4 Press Enter to save the setting 5 Press Esc repeatedly to return to t...

Page 266: ...tion after one minute without user intervention 7 2 10 Setting and activating summer winter time The system automatically switches between summer and winter time 7 3 Using KAESER CONNECT Using a PC wi...

Page 267: ...e PC and the SIGMA CONTROL 2 2 In the web browser enter the controller s IP address The Login window opens Fig 10 Login window 1 Login window 2 User name 3 Generated password 4 Login key 3 Enter the u...

Page 268: ...guage selection 2 Language selection window 3 Select a language 4 Selected language 7 Select the required language 3 KAESER CONNECT is displayed in the selected language 7 3 2 Displaying the system st...

Page 269: ...ocal menu can be displayed at your PC 1 Simply click in the display of the operating mode The main menu is displayed Fig 14 Main menu 2 You now may click the Status menu The system displays the corres...

Page 270: ...ed The last 20 mi nutes are displayed in a graph The system updates the graph every ten seconds whilst the current time is displayed Moving the mouse pointer across the graph calls up a ruler The time...

Page 271: ...on to enlarge significant curve developments Highlight a specific area within the graph by drawing a rectangle with the mouse pointer pressed The selected area will be enlarged as soon as the mouse po...

Page 272: ...larged zoom in function 5 Click the Zoom out 3 arrow key Time range is enlarged zoom out function 7 3 4 Displaying messages The following messages are shown Current messages Compressor messages System...

Page 273: ...7 2 7 Subsequently the write mode is activated The write mode is granted only to one person at a time If a second user attempts to log on in write mode he will be refused by the system The system will...

Page 274: ...he Log on for write access window opens Fig 20 Log on for write access window 1 Log on for write access window 2 User name 3 Password 4 OK key 5 Esc key 3 Enter your own user name 4 Enter your own pas...

Page 275: ...ype Customer 6 11 Select the status Activated 7 12 Click Add 8 The new user name has been added to the user list Result A new user account has been created and activated Updating user accounts Similar...

Page 276: ...u 2 Unit of pressure 3 Unit of temperature Converting units to US values Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed 1 Select the Settings menu The system displays the Settings menu 2...

Page 277: ...ONNECT for SIGMA CONTROL 2 is displayed 1 Open the Data backup menu The system displays the Data backup menu Fig 23 Data backup 1 Data backup menu 2 Selection 3 Data backup key 2 Select 2 3 Click the...

Page 278: ...ng pressure of the safety relief valve on the oil separator tank pE Pressure increase Setting pE SP Switching point for pressure increase upper safety limit for machine maximum pressure in an external...

Page 279: ...t in pressure min Display For design reasons pressure can only be built up above this value Tab 52 Compressor pressure parameters Parameters correspond to the following specifications 7 4 1 Displaying...

Page 280: ...ng limits for system setpoint pressure Cut in pressure min The machine switches to LOAD under the following condition System pressure SP pA pB switching differential Tab 54 Pressure condition for LOAD...

Page 281: ...activated 1 Select Configuration Pressure control Pressure settings see Section 7 4 1 2 Press the DOWN key repeatedly until the following is displayed as the active line 89 psi 08 15 17 6 F 5 2 2 Pre...

Page 282: ...ariable frequency drive SFC The pressure rise value dpfC is the limit from which the machine switches to IDLE This value can be between 2 9 psi and 5 8 psi The factory setting is 2 9 psi The pressure...

Page 283: ...ching the machine to IDLE you can deactivate the LOAD IDLE key on the operating panel Precondition Password level 2 is activated The Configuration Pressure control Load control menu is selected see Se...

Page 284: ...ammed clock mode No clock time program entered 7 5 1 Holidays Not set 7 5 2 Remote start e g from a control centre Deactivated 7 5 3 IDLE venting Activated 7 5 4 Automatic restart after power failure...

Page 285: ...the following cycles Mon Thu Mon Fri Mon Sat Mon Sun Sat Thu You can also program an OFF time shutdown periods see section 7 5 2 Example Machine ON Weekdays 6 30 17 00 Fridays 6 30 15 00 Machine OFF...

Page 286: ...0 Use UP to specify the settings for the minutes 11 Press Enter to accept the settings The display stops flashing and the time hours minutes is set 89 psi 08 15 17 6 F 6 Compressor clock Menu 01 Mon F...

Page 287: ...the operation with a timing program 7 5 2 Setting up the holiday period In addition to the fixed cycles of a timing program or timer you can also specify a longer lasting standstill time For example y...

Page 288: ...rt to remote mode Press the Remote key If necessary activate the Clock key and configure the clock program see section7 5 1 2 If required assign the remote contact to another input Press the Remote ke...

Page 289: ...e control key Precondition The electrical connection has been made Password level 2 is activated The display shows the operating mode 1 Press Enter The main menu is displayed 2 Select the Configuratio...

Page 290: ...be further assigned 1 Press the DOWN key repeatedly until the following is displayed as active line 89 psi 08 15 17 6 F 5 4 1 Compressor on Menu Local mode Key Remote mode Key RC RC DI 1 12 ok Remote...

Page 291: ...Start 01 01 12 00 00 End 01 01 12 3 Press Enter to switch into setting mode The check box for the Venting period function will flash 4 Press the UP key 89 psi 08 15 176 F 5 4 2 Compressor off Menu Ve...

Page 292: ...he Compressor start menu is displayed 89 psi 08 15 17 6 F 5 4 Compressor start Menu 1 Compressor on Active line 2 Compressor off Autostart Automatic restart activated Target 10 s Actual 0 s Deactivati...

Page 293: ...ted Target 10 s Actual 0 s Set expiring delay period 2 Press Enter to switch into setting mode The display for the delay time Setpoint flashes 3 Change the time using the DOWN or UP keys 89 psi 08 15...

Page 294: ...5 17 6 F 5 3 Control mode Menu Local mode DUAL Active line 1 Venting period Venting period menu 2 DUAL 3 QUADRO 3 Press Enter to switch into setting mode The display for DUAL control mode flashes 89 p...

Page 295: ...9 psi 08 15 17 6 F 5 3 2 DUAL Menu Idle period Target 240 s Actual 0 s Active line 3 Press Enter to switch into setting mode The current idle time of 240 s flashes 89 psi 08 15 176 F 5 3 2 DUAL Menu I...

Page 296: ...89 psi 08 15 17 6 F 5 3 3 QUADRO Menu Min run period Target 260 s Actual 0 s Active line with changed setpoint value for minimum run time Unloaded period Target 260 s Actual 100 s Changed setpoint val...

Page 297: ...ted dryer is kept constant within narrow limits under this method of control by cycling the refrigerant circulation Precondition Access level 2 is activated 1 In operating mode switch to the main menu...

Page 298: ...nfiguration Refrigeration dryer menu is selected 1 Press DOWN repeatedly until Temperature is displayed as the active line 89 psi 08 15 17 6 F 5 9 Refrigeration dryer Menu Temperature Active line temp...

Page 299: ...t call KAESER Service immediately An authorized KAESER service representative eliminates the fault and exe cutes a reset Precondition The operator decides Compressed air quality has a higher priority...

Page 300: ...u is selected 1 Press DOWN repeatedly until Error operation without RD is displayed as the active line 89 psi 08 15 17 6 F 5 9 Refrigeration dryer Menu Error operation without RD Active line active Ru...

Page 301: ...med time pulse 7 8 3 Tab 59 Local operating mode local mode Adjust the system setpoint pressure as described in Section 7 4 Overview Enter access level 2 Select Configuration Set adjust the clock prog...

Page 302: ...No Weekday Time System setpoint pres sure 01 Mon Fri 06 30 pA on 02 Mon Fri 12 00 pB on 03 Mon Fri 13 00 pA on 04 Mon Thu 17 00 pB on 05 Fri 16 00 pB on Tab 60 Example of system pressure changeover s...

Page 303: ...s minutes is set 11 Press the Right key once 12 Press Enter The display for the system setpoint pressure pA pB flashes 13 Use UP or DOWN to change the setting for pA or pB 14 Specify further switching...

Page 304: ...ary Set clock periods pA and pB Select starting time for pA or pB Select the pA pB Cycle operating mode see Section 7 8 3 3 7 8 3 1 Setting clock periods pA and pB Keep to the order of the configurati...

Page 305: ...e h flashes 89 psi 08 15 176 F 5 2 3 Load control Menu pA pB Cycle pA 10 h 10 h pB 18 h 18 h 1 Start pA 06 30 Active line starting time 4 Press UP to set the hours 5 Press the Right key The starting t...

Page 306: ...r receives the instruction LOAD IDLE or local operation via the Profibus master e g SIGMA AIR MANAGER or VESIS The system setpoint pressures pA and pB are irrelevant for the LOAD IDLE signals 7 9 2 Ma...

Page 307: ...Further information Examples of clock programs for equal machine loading are given in section 7 9 9 7 9 2 Configuring Profibus mode SIGMA AIR MANAGER or VESIS Overview Profibus DP V0 Retrofit Kit req...

Page 308: ...ug wiring 1 Terminal 1A 2 Terminal 1B 3 Terminal 2A 4 Terminal 2B 5 Slide switch terminating resistor 7 Initial Start up 7 9 Configuring the machine for master control 9_9450 03USE Service manual Cont...

Page 309: ...r master control excerpt Fig 27 Electrical diagram example with SIGMA AIR MANAGER 7 Initial Start up 7 9 Configuring the machine for master control 90 Service manual Controller SIGMA CONTROL 2 SCREW F...

Page 310: ...tting mode The operating mode display flashes 89 psi 08 15 17 6 F 5 2 3 Load control Menu Local mode pA Remote mode pB Active line Key remote 1 pA pB Clock 3 Use UP or DOWN to set pB operating mode 4...

Page 311: ...he SIGMA CONTROL 2 3 Press the screwdriver down until the fin breaks 4 Break all other fins in the same manner 5 Remove the plastic cover Inserting and fixing the communication module Align the commun...

Page 312: ...y is activated The machine is parameterized as a slave in the bus master The bus master is operational Fig 30 Front plate of the PROFIBUS communication module 1 PROFIBUS communication module 2 Operati...

Page 313: ...Com Module Menu Type Profibus Detected communication module Com Module Start Reset Slave No 102 Active line Bus alarm Result Slave address 102 is set Setting the reaction for a bus fault Exchange of...

Page 314: ...line Timeout 5 s 2 Press Enter to switch into setting mode 3 Use UP or DOWN to adjust the setting 4 Press Enter to accept the setting Activate the communications module 1 Press UP five times The Com...

Page 315: ...6 F 8 Communication Menu 1 Ethernet Active line 2 Com Module Key remote 3 Press DOWN twice The Remote control key is displayed as the active line 4 Press Enter to switch into setting mode 5 Press UP o...

Page 316: ...diagram Precondition Communications module from Profibus DP V0 retrofit kit is installed The electrical connection to the bus master is made Access level 2 is activated The required data has been pro...

Page 317: ...enu Status Counter 0 No error Type Profibus Com Module Start Slave No 103 Active line current slave address assigned 3 Set the slave address with UP or DOWN 4 Press Enter to accept the setting Result...

Page 318: ...e configuration steps as described in table 63 Controller Procedure Chapter Both Establishing the electrical connection 7 9 4 1 Both Set system pressure setpoints pA and pB The pressure for switch ing...

Page 319: ...e machine s control cabinet using an EMC connection 2 Lead the Ethernet cable through the cable ducts to SIGMA CONTROL 2 Use the wiring path in the 24V range blue wiring of the ducts 3 Install the Eth...

Page 320: ...ontrol key 1 Select the Configuration Pressure control Load control menu Local mode line is displayed as the active line 2 Press DOWN three times The Remote control key is displayed as the active line...

Page 321: ...ess the Right key 7 Press Enter to switch into the setting mode for system setpoint pressure pB 8 Use UP or DOWN to set the timer peri od for the system setpoint pressure pB 9 Press Enter to accept th...

Page 322: ...point pB in the same manner Activating the Remote control key 1 Select the Configuration Pressure control Load control menu Local mode line is displayed as the active line 2 Press DOWN three times Th...

Page 323: ...Enter to switch into setting mode 10 Enter the IP address of the communication partner master 11 Press Enter to accept the setting 7 9 5 Configuring for master control using the LOAD remote contact e...

Page 324: ...ated The Configuration Pressure control Load control menu is selected Set the LOAD remote contact operating mode 1 Press UP or DOWN repeatedly until Remote mode is displayed as the active line 2 Press...

Page 325: ...lt The operating mode is now configured 7 9 5 3 Adjusting pressure increase pE Adjust the pressure increase pE as described in section 7 4 2 3 Further information Detailed information on the pressure...

Page 326: ...ontroller on DOR 1 03 messages from the compressor to the MVS 8000 controller Contact A open SIGMA CONTROL 2 controls with system setpoint pressurepB Contact A closed SIGMA CONTROL 2 controls using a...

Page 327: ...nu pA pB DO DOR 1 04 No input assigned Load RC DI 1 13 ok loc load RC DI 1 09 ok Active line Key idle 3 Use UP to select a new input for local LOAD remote contact 4 Press Enter to accept the setting R...

Page 328: ...ey remote is displayed as the active line 2 Press Enter to switch into setting mode The check box for Key remote flashes 89 psi 08 15 17 6 F 5 2 3 Load control Menu Remote mode loc load RC Key remote...

Page 329: ...ly until Load RC is displayed as the active line 2 Press Enter to switch into setting mode DI flashes 89 psi 08 15 176 F 5 2 3 Load control Menu pA pB RC DI 1 05 pA pB DO DOR 1 04 Load RC DI 1 13 ok A...

Page 330: ...the UP key to select operating mode pA pB RC 4 Press Enter to accept the setting Result Operating mode pA pB remote contact is selected 7 9 7 2 Assigning the remote contact input A spare input can be...

Page 331: ...conventional machine without SIGMA CONTROL 2 of the same capacity are to run in sequence as base load or peak load ma chines Proposal Set adjust the clock program or clock on SIGMA CONTROL 2 Select l...

Page 332: ...tem setpoint pressure pA 07 S0629 A K3 A1 A2 Fig 34 Machine with pressure switch regulation A Floating relay contact SIGMA CONTROL 2 Make the electrical connection according to the diagram Setting the...

Page 333: ...d The electrical connection made select spare contact from the machine s electrical diagram 1 Select Configuration Pressure control Load control 2 Press the DOWN key repeatedly until the following is...

Page 334: ...ressure switch to be in between When pB is activated for the periods of low demand the SK machine automatically functions as the base load machine Set the required values for a clock program on SIGMA...

Page 335: ...ngs menu is displayed 2 Press DOWN repeatedly until Setpoint pressure pA SP is displayed as the active line 89 psi 08 15 17 6 F 5 2 2 Pressure settings Menu Setpoint pressure pA SP 123 psi SD 7 psi Ac...

Page 336: ...e for the first switching point Define further switching points Precondition Password level 2 is activated The Configuration Pressure settings Load control menu is selected Configure the switching pro...

Page 337: ...15 176 F 5 2 3 1 pA pB Clock Menu Reset 01 Mon Fri 00 00 pB Active line First switching point set weekdays 02 Mon Fri 00 00 pB Weekday Second switching point 03 n a 00 00 pB 04 n a 00 00 pB 11 Enter...

Page 338: ...t pressure flashes 4 Use UP to specify the settings for the system setpoint pressure pA or pB 5 Press Enter to accept the settings 89 psi 08 15 17 6 F 5 2 3 1 pA pB Clock Weekday setting Reset Current...

Page 339: ...r 24 hours The compressors start with a system set point pressure pB at 00 00 hours A timer triggers the switch between system set point pressurepA and system set point pressure pB local operating mod...

Page 340: ...t point pressure 01 Mon 00 00 pA On 02 Mon 21 00 pB On 03 Tue 18 00 pA On 04 Wed 15 00 pB On 05 Thu 12 00 pA On 06 Fri 09 00 pB On 07 Sat 06 00 pA On 08 Sun 03 00 pB On Tab 67 Example for a clock prog...

Page 341: ...hes 3 Press UP to deactivate the email function 4 Press Enter to accept the setting The email function is deactivated 89 psi 08 15 176 F 8 1 3 E mail Menu active Active line deactivate activate email...

Page 342: ...ccept the setting 6 Press Escape repeatedly to return to the main menu Result Suppression interval is set 7 11 Configuring input and output signals The controller s binary and analog inputs and output...

Page 343: ...he EMERGENCY OFF button has been pressed Tab 68 Assigned output signals Overview Navigate to the Configuration I O periphery DO functions menu for the configuration Access level 2 is activated Assigni...

Page 344: ...om analog measuring sensors of pressure or temperature for example Of these two each are assigned to pressure and temperature transducers two further inputs can be assigned to freely selectable sensor...

Page 345: ...89 psi 08 15 176 F 5 7 2 Analogue values Menu 1 AnMod 2 AI Active line 3 AO 3 Press Enter The menu for pressure transducers temperature sensors and freely selectable sensor types is displayed 4 Press...

Page 346: ...itch into setting mode The Unit display of the sensor flashes 7 Use the UP and DOWN keys to select characters from the character set in order to assign the unit to the sensor signal 89 psi 08 15 17 6...

Page 347: ...tting ok is displayed The measured value is displayed in the active line 7 11 2 4 Determining the type of current signal 0 4 20 mA 1 Press DOWN three times 2 Press Right once to set the type of curren...

Page 348: ...now be displayed in the Performance data menu see chapter 8 7 7 11 3 Displaying additional binary input signals As well as the defined fault and warning messages there are six additional freely select...

Page 349: ...ernal message 3 4 External message 4 5 External message 5 6 External message 6 7 11 3 2 Entering the message text External message 1 is shown as example 1 Press Enter External message 1 is displayed a...

Page 350: ...and activated 7 11 3 4 Setting the time delay The delay can be set between 0 01 and 600 seconds The delay is counted down from 600 with the DOWN key and counted upwards from zero in 0 01 second incre...

Page 351: ...ssign and activate the output 1 Press DOWN repeatedly until Output is displayed as the active line 2 Press Enter to switch into setting mode The Output display flashes 3 Select the output with the UP...

Page 352: ...via an output it makes sense to have these messages acknowledged by the control center Acknowledging the message without correcting the cause however can lead to machine damage Safety relevant message...

Page 353: ...ent function 1 Press Enter to switch into setting mode Key flashes 2 Press UP The Key RC menu is displayed 89 psi 08 15 176 F 5 5 Acknowledgement Menu Remote mode Key RC Active line with Key Remote co...

Page 354: ...active line is displayed 89 psi 08 15 17 6 F 5 5 Acknowledgement Menu Remote mode Key RC Key remote RC ack DI 1 11 Active line 2 Press Enter DI flashes 3 Use UP to select the desired input 4 Press En...

Page 355: ...Profibus connection from a master controller Not necessary External pressure transducer is connected to SIGMA CONTROL 2 Assign AII Characteristics pressure transducer 4 20 mA 0 232 psig USS protocol...

Page 356: ...Network actual pressure sub menu is displayed as the active line 4 Press Enter The Network actual pressure menu is displayed 89 psi 08 15 17 6 F 5 2 4 Network actual pressure Menu pNloc 89 psi Active...

Page 357: ...sult The input for the external transducer is now activated You have connected an external pressure transducer to a frequency converter USS proto col Assign the input FC USS to the pressure transducer...

Page 358: ...em pressure pNloc the time and the airend discharge temperature are dis played in the first line of the display 89 psi 08 15 12 2 F Alarm Key off pA off Run 0 h Load 0 h Maintenance in 2000 h 2 Contin...

Page 359: ...green 2 Press the ON key The ON LED lights green If a power failure occurs the machine is not prevented from restarting automatically when power is resumed It can restart automatically as soon as pow...

Page 360: ...ENCY STOP button remains latched after actuation The compressor s pressure system is vented and the machine is prevented from automatically re starting Switching on Precondition The fault has been rec...

Page 361: ...row before acknowl edging the fault message Further information Please refer to the 9 2 operating manual for a list of possible fault messages during operation Warning message If maintenance work is t...

Page 362: ...pressor messages Diagnostic messages System messages 2 Segment Message number Type of message Message status Message date Message time 3 Text message text Tab 72 Information of a message Message type...

Page 363: ...fault or warning message 89 psi 08 15 176 F 1 1 1 Current messages Menu 0021 S q 16 04 13 13 32 49 Active line Refrigeration dryer T 0015 W q 21 01 11 13 06 43 Bus alarm 0911 D q 21 01 11 13 07 47 AIR...

Page 364: ...ating mode The operating mode is displayed in 4 segments example On off switching via Machine state LOAD control via State of the LOAD control Key on pA Idle Tab 74 Operating mode display 1 In operati...

Page 365: ...fault registered LOAD control via pA System setpoint pressure pA pB System setpoint pressure pB pE Raised system pressure pE at a dubious LOAD signal Load RC Remote contact external LOAD signal Load...

Page 366: ...with the Enter key 2 Select the Performance data menu An overview of the analog data is displayed 89 psi 08 15 17 6 F 2 Performance data Menu System pressure pNloc 89 psi Local System pressure pNloc...

Page 367: ...6 F 3 Operating data Menu 1 Operating hours Active line 2 kWh counter Load valve on 383 Total number of switching actions Changing the operating hours The running times of the compressor motor and th...

Page 368: ...consecutively Messages 0081 to 0095 are customer specific and undefined Complete them with your defined message text and interpretation Message Meaning 0001 O Load control pA The machine is regulated...

Page 369: ...0025 O Setpoint pressure pA The value for pA is output 0026 O Setpoint pressure pB The value for pB is output 0027 O Power OFF ON Request Switch the power supply off and on 0028 O DYNAMIC motor tempe...

Page 370: ...ult IOSlot5 0205 O IOSlot6 Undervoltage error 50 The internal voltage monitoring reports low voltage fault IOSlot6 Tab 76 Operational messages 8 9 Setting the maintenance interval Example Changing the...

Page 371: ...ct conclusion of the test Resetting When the check mode is activated monitoring of internal pressure blow off protection if provided and regulation of network pressure are deactivated The measured val...

Page 372: ...ox pRV 232 psi pi 36 psi Relief valve activating pressure Reset 4 Excessive noise is caused when the safety relief valve blows off Close all access doors replace and secure all removable panels Wear h...

Page 373: ...x 8 11 Checking the temperature sensor and overheating shutdown func tion The machine should shut down if the airend discharge temperature ADT reaches a maximum of 230 F SIGMA CONTROL 2 will simulate...

Page 374: ...ischarge temperature ADT display changes to 226 F The test mode is now activated 89 psi 08 15 16 3 F 9 1 T V inspection Menu Airend discharge temperature ADT Active line Offset 95 F ADT 226 F Offset a...

Page 375: ...etting SIGMA CONTROL 2 will display the highest measured value if the test for switching off at overtem perature is aborted Activate the check box for reset in order to reset the stored value Activate...

Page 376: ...larm upon the sig nal s arrival Consequences The red LED flashes The controller switches the machine off Alarm messages are identified with the letter A The message numbers are not numbered consecutiv...

Page 377: ...wn of the first fan motor Investigate cause of shut down Reset the overload relay 0012 A Access doors Door open interlocked panel removed while the machine is running Fit and secure all panels and clo...

Page 378: ...contactor does not open Check main contac tor and wiring 0041 A Mains voltage Second power failure Check power supply voltage Check the door inter lock switch 0042 A Back pressure stop Back pressure...

Page 379: ...rise dT dt The rate of rise of the air end discharge temperature is too fast Check the cooling oil level 0062 A Refrigeration dryer p Refrigerated dryer Pressure too high in the re frigerant circuit...

Page 380: ...2 A Oil air cooler fan Overcurrent Overload shut down of the first fan motor Investigate cause of shut down Reset the overload relay 0200 A Compressor motor USS alarm Frequency converter fault Contact...

Page 381: ...c messages A diagnostic message causes the machine to shut down Diagnostic messages are identified with the letter D They provide information on the status of the controller the connected input and ou...

Page 382: ...il filter 0013 W Air filter p Air filter clogged Change the air filter 0015 W Bus alarm The bus link via the Pro fibus DP interface is in terrupted Check the bus cables and plugs 0025 W Oil separator...

Page 383: ...d The permissible number of motor starts was ex ceeded in the last 24 hours Extend the idle period Increase the capacity of the air receiver Increase the cross section of piping between compressor and...

Page 384: ...conditions within specified limits 0060 W Start temperature The airend temperature is too low 35 F Keep ambient conditions within specified limits 0061 W Compressor T The airend discharge temperature...

Page 385: ...age 0081 W 0082 W 0083 W 0084 W 0085 W 0086 W 0087 W 0088 W 0089 W 0090 W 0091 W 0092 W 0093 W p Switch pi 0094 W T Switch ADT 0095 W p Switch pN Tab 80 Warning messages and remedies 9 Fault Recogniti...

Page 386: ...ONTROL 2 and the I O modules are maintenance free Use basic safety instructions and safety instructions for working on live components 10 Maintenance 10 1 Maintenance Work 9_9450 03USE Service manual...

Page 387: ...ed air system the security of genuine KAESER spare parts increased legal certainty as all regulations are kept to Why not sign a KAESER AIR SERVICE maintenance agreement Result Your advantage lower co...

Page 388: ...g the DOWN key to display further settings 89 psi 08 15 17 6 F 5 1 1 1 SIGMA CONTROL 2 MCS Menu SN x xx xx Prodrive Manufacturer PN 6309 1000 7900 Part number SN 10 34 000 961 Serial number MFGDT 2010...

Page 389: ...s service manual 12 3 Storage Follow the instructions in the machine s service manual 12 4 Transporting Follow the instructions in the machine s service manual 12 5 Disposal Follow the instructions i...

Page 390: ...Project Florence12 L 00478 Order No 10357405 Technical Documentation Compressor Typ ESD 442 SFC 14 bar a ac Helium Compressor No ESD 2C Serial No 1205 5 Spare Parts List...

Page 391: ...Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 No TTL ESD_2C_10357405_10_00 E Manufacturer KAESER KOMPRESSOREN 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www...

Page 392: ...KKW GBASE 1 00 en ERSATZTEILE 10357405_10 ESD 2C 20130903 115349...

Page 393: ...ibility 1 1 Safely dealing with sources of danger 1 1 2 Spares for service and repair 3 1 3 ESD 442 SFC 14 bar 3 Contents No TTL ESD_2C_10357405_10_00 E Spare parts Screw compressor ESD 442 SFC 14 bar...

Page 394: ...Contents ii Spare parts Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 No TTL ESD_2C_10357405_10_00 E...

Page 395: ...List of Illustrations No TTL ESD_2C_10357405_10_00 E Spare parts Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 iii...

Page 396: ...List of Illustrations iv Spare parts Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 No TTL ESD_2C_10357405_10_00 E...

Page 397: ...Tab 1 Advise others that the machine is being serviced 1 Tab 2 Machine data 3 List of Tables No TTL ESD_2C_10357405_10_00 E Spare parts Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 v...

Page 398: ...List of Tables vi Spare parts Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 No TTL ESD_2C_10357405_10_00 E...

Page 399: ...or indirect contact Before starting any work on electrical equipment Switch off and lock out the power supply isolator and check that no voltage is present Switch off any external power sources These...

Page 400: ...ine noise to a tolerable level This function will be effective only if the enclosure is closed Operate the machine only with intact sound insulation Wear hearing protection if necessary Operating flui...

Page 401: ...should be referred to KAESER Correct use of information will be fully supported During work please comply with the safety instructions provided in the current operating manual for this machine Make s...

Page 402: ...1 Safety and Responsibility 1 3 ESD 442 SFC 14 bar 4 Spare parts Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 No TTL ESD_2C_10357405_10_00 E...

Page 403: ...1 Safety and Responsibility 1 3 ESD 442 SFC 14 bar No TTL ESD_2C_10357405_10_00 E Spare parts Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 5...

Page 404: ...1 Safety and Responsibility 1 3 ESD 442 SFC 14 bar 6 Spare parts Screw compressor ESD 442 SFC 14 bar ESD 2C 1204 1205 No TTL ESD_2C_10357405_10_00 E...

Page 405: ...Project Florence12 L 00478 Order No 10357405 Technical Documentation Compressor Typ ESD 442 SFC 14 bar a ac Helium Compressor No ESD 2C Serial No 1205 6 Performance test by helium 100714...

Page 406: ...e Screw compressor Model ESD 442 SFC 14 bar Serial number 1205 Year of manufacture 2013 Kaeser part number ESD 2C Kaeser job number 10357405 Date of test 30 08 2013 Technical specification M SD 1014 7...

Page 407: ...as inlet temperature Gas suction pressure Outlet pressure Mass throughput Total power consumption 20 Hz 299 1 K 1 05 bar abs 14 bar 29 72 g s 108 2 kW 40 Hz 300 5 K 1 05 bar abs 14 bar 61 72 g s 197 3...

Page 408: ...ct Florence12 L 00478 Order No 10357405 Technical Documentation Compressor Typ ESD 442 SFC 14 bar a ac Helium Compressor No ESD 2C Serial No 1205 7 Measurement record for units with suction side gas s...

Page 409: ...D 327 K Unit outlet temperature T OUT K Gas meter inlet temperature TB1 299 1 K Gas meter outlet temp TB2 K Suction pressure pA 1 05 bar abs Unit outlet pressure pe 14 0 bar abs Gas meter working pres...

Page 410: ...348 K Unit outlet temperature T OUT K Gas meter inlet temperature TB1 300 5 K Gas meter outlet temp TB2 K Suction pressure pA 1 05 bar abs Unit outlet pressure pe 14 0 bar abs Gas meter working press...

Page 411: ...as meter inlet temperature TB1 301 2 K Gas meter outlet temp TB2 K Suction pressure pA 1 05 bar abs Unit outlet pressure pe 14 0 bar abs Gas meter working pressure pB 5 94 bar abs Gas meter working vo...

Page 412: ...Project Florence12 L 00478 Order No 10357405 Technical Documentation Compressor Typ ESD 442 SFC 14 bar a ac Helium Compressor No ESD 2C Serial No 1205 8 Quality Dimensions Material Surface 100713...

Page 413: ...manufacture 2013 Kaeser part number ESD 2C Kaeser job number 10357405 Date of test 29 08 2013 Technical specification M SD 1014 7 Type of test Material certificate airend Component Part number Materia...

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