KAESER KOMPRESSOREN FSD SIGMA CONTROL 2

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Service Manual

Screw

Compressor

FSD

SIGMA CONTROL 2

Manufacturer:

KAESER KOMPRESSOREN

96410

Coburg·

Box

2143·

GERMANY·

Tel. +49-(0)9561-6400· Fax +49-(0)9561-640130

http://www.kaeser.com

Main Page

Table of Contents3
Using this Document11
Further Documents11
Copyright11
Symbols and Labels11
Warnings11
Tab. 1 Danger Levels and Their Definition (Personal Injury)11
Potential Damage Warnings12
Other Alerts and Their Symbols12
Tab. 2 Danger Levels and Their Definition (Damage to Property)12
Technical Specifications Nameplate14
Optional Accessories14
Weight14
Tab. 3 Nameplate14
Tab.4 Optional Accessories14
Select Temperature15
Ambient Conditions15
Tab. 5 Machine Weight15
Tab. 6 Select T Emperature15
Tab. 7 Ambient Conditions15
Ventilation16
Fig.1 Maximum Relative Humidity of Intake Air16
Tab. 8 Overview Ventilation (50 Hz)16
Pressure17
Delivery17
Tab. 9 Overview Ventilation (60 Hz)17
Tab. 10 Pressure Relief Valve Activating Pressure (50Hz)17
Tab. 11 Pressure Relief Valve Activating Pressure (60Hz)17
Cooling Oil Recommendation18
Tab. 12 FAD (50 Hz)18
Tab. 13 FAD (60 Hz)18
Tab.14 Cooling Oil Recommendation19
Tab. 15 Cooling Oil Recommendation (Food Processing)19
Cooling Oil Charge20
Motors and Power21
Compressor Drive Motor21
Fan Motor21
Tab. 20 Compressor Drive Motor21
Tab. 21 Compressor Motor (60Hz)21
Fan Motor22
Tab. 22 Fan Motor (Option K1)22
Tab. 23 Fan Motor (Option K1. 60Hz)22
Tab. 24 Fan Motor (Option K2. 50Hz)22
Tab. 25 Fan Motor (Option K2. 60Hz)22
Noise Emission23
Powersupply23
Power Supply Specifications23
Tab. 26 Noise Emission23
Tab. 27 Noise Emission23
Mains Frequency: 50 Hz24
Mains Frequency: 60 Hz24
Water Cooling25
Design Data25
Cooling Water Quality26
Available Heat Capacity27
Tab. 35 Cooling Water Quality27
Tab. 36 Heat Capacity (Option W1)27
Safety and Responsibility28
Basic Instructions28
Specified Use28
Improper Use28
User's Responsibilities28
Observe Statutory and Universally Accepted Regulations28
Determining Personnel29
Adherence to Inspection Schedules and Accident Prevention Regulations29
Dangers30
Safely Dealing with Sources of Danger30
Tab.37 Inspection Intervals According to Ordinance on Industrial Safety and Health30
Safe Machine Operation32
Organisational Measures34
Danger Areas34
Safety Devices35
Safety Signs35
Fig.2 Location of Safety Signs35
Emergency Situations36
Correct Fire Fighting36
Tab. 39 Safety Signs36
Treating Injuries from Handling Cooling Oil37
Warranty37
Environment Protection38
Design and Function Enclosure39
Machine Function39
Fig.3 Enclosure Overview39
Floating Relay Contacts40
Fig.4 Machine Layout40
Options41
Machine Mountings41
Water-Cooling41
Cooling Air Filter Mat41
Fig.5 Machine Mountings41
Fig.6 Water-Cooling (Option K2)41
Prepared Tor Extemal He at Recovery42
Control Air Connection Tor Modulating Control42
Fig.7 Cooling Air Filter Mat (Option K3)42
Operating Modes and Control Modes43
Operating Modes43
Control Modes43
Safety Devices45
Operating Panel SIGMA CONTROL 245
Fig.8 Keys45
Fig.9 Indicators46
Tab.42 Buttons46
Fig.10 RFID Sensor Field47
Tab. 43 Displays47
Installation and Operating Conditions49
Ensuring Safety49
Installation Conditions49
Determining Loeation and Clearances49
Ensuring the Machine Room Ventilation50
Fig.11 Recommended Machine Placement and Dimensions [MM]50
Exhaust Duct Design51
Operating the Machine in a Compressed Air Network51
Installation52
Ensuring Safety52
Reporting Transport Damage53
Connecting the Machine with the Compressed Air Network53
Connecting the Power Supply53
Fig.12 Compressed Air Pipework53
Connecting the Condensate Drain54
Options55
Anchoring the Machine55
Connecting the Cooling Water55
Fig.13 Condensate Drain Dimensions [MM]55
Connecting the Extemal Heat Recovery System56
Connecting External Control Air56
Fig.14 Connecting the Cooling Water56
Initial Start-Up Ensuring Safety58
Instructions to be Observed before Commissioning or Re-Commissioning59
Checking Installation and Operating Conditions59
Tab. 45 Re-Commissioning after Storage59
Setting the Overload Protection Cut-Out60
Setting the Motor Overload Proteetion Switch60
Filling Cooling Oil into the Airend60
Tab. 46 Installation Conditions Checklist60
Fig.15 Inlet Valve Filling Port61
Fig.16 Coupling61
Activaling and Deactivating the MODULA Tlng Control62
Switching MODULATING Control to External Control Air62
Fig.17 MODULA Tlng Contro!: Setting the Shut-Off Valve62
Tab.47 MODULATING Control: Setting the Shut-Off Valve62
Starting the Machine Tor the First Time63
Setting the Set Point Pressure63
Setting the Display Language63
Operation65
Switching on and off65
Switching on65
Switching off65
Fig.18 Switching on and off65
8.2 Switching off in an Emergency and Switching on Again66
8.3 Switching on and off from a Remote Control Centre66
Fig.19 Switching off in an Emergency66
Switching on and off with the Clock67
Fig.20 Switching on and off from a Remote Control Centre67
Tab.48 Machine Identification67
Tab. 49 Remote Control Identification67
Interpreting Operation Messages68
Acknowledging Alarm and Warning Messages68
Fig.21 Switching on and off with the Clock68
Tab.50 Machine Identification68
Fig.22 Acknowledging Messages69
Fault Recognition and Rectification71
Basic Instructions71
Other Faults71
Tab. 51 Other Faults and Actions72
Maintenance73
Ensuring Safety73
Following the Maintenance Plan74
Logging Maintenance Work74
Resetting Maintenance Interval Counters74
Regular Maintenance Tasks74
Cooling Oil: Change Interval75
Tab. 52 Regular Maintenance Tasks75
Regular Service Tasks76
Control Cabinet: Clean or Renew the Filter Mat76
Tab.53 Cooling Oil: Change Intervals76
Cooler Maintenance77
Fig.23 Switching Cabinet Ventilation77
Water-Cooling Maintenance78
Fig.24 Clean Cooler/Radiator78
Cleaning or Renewing the Cooling Air Filter Mat79
Fig.25 Cooling Air Filter Mat79
Maintaining the Heat Recovery System80
External Heat Recovery System80
Changing the Air Filter80
Motor Maintenance81
Fig.26 Air Filter Maintenance81
Fig.27 Drive Motor Maintenance82
Checking the Coupling83
Fig.28 Checking the Coupling83
Testing the Pressure Relief Valve84
Checking the Overheating Safety Shutdown Function84
Checking the Cooling Oillevel85
Venting the Machine (De-Pressurising)85
Fig.29 Checking the Cooling Oil Level85
Fig.30 Venting the Machine86
10.15 Replenishing the Cooling Oil87
Venling the Machine (De-Pressurising)87
Fig.31 Replenishing the Cooling Oil87
Topping up with Cooling Oil and Trial Run88
Changing the Cooling Oil89
Fig.32 Changing the Cooling Oil, Oil Separator Tank90
Fig.33 Changing the Cooling Oil, Oil Cooler91
Fig.34 Changing the Cooling Oil, Airend92
Changing the Oil Filter93
Changing the Oil Separator Cartridge94
Fig.35 Changing the Oil Filter94
Fig.36 Changing the Oil Separator Cartridge95
Condensate Drainage Maintenance96
Checking Condensate Drainage96
Cleaning the Condensate Drain97
Fig.37 Checking Condensate Drainage97
Fig.38 Cleaning the Condensate Drain98
Assembling Ssexible Pipe Connections99
Fig.39 Assembling Flexible Pipe Connections99
Documenting Maintenance and Service Work100
11 Spares, Operating Materials, Service101
Note the Nameplale101
Ordering Consumable Parts and Operating Ssuids/Materials101
Kaeser Air Service101
Service Addresses102
Spare Parts for Service and Repair102
12 Decommissioning, Storage and Transport107
Putting out of Operation107
Packing107
Storage107
Transport108
Safety108
Transport with a Forklift Truck108
Transport Wilh a Crane108
Fig.40 Transport with a Forklift Truck108
Disposal109
Fig.41 Transport with a Crane109
13 Annex110
Pipeline and Instrument Flow Diagram (P+I Diagram)110
Pipeline and Instrument Flow Diagram (P&I Diagram) MODULATING Control113
Dimensional Drawing116
Electrical Diagram120

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KAESER KOMPRESSOREN FSD SIGMA CONTROL 2 Specifications

General

Brand	KAESER KOMPRESSOREN
Model	FSD SIGMA CONTROL 2
Category	Air Compressor
Language	English

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Table of Contents

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