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KAESER
Air Compressor
Aircenter SX 7.5
KAESER Aircenter SX 7.5 User Manual
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Service manual
Screw compressor
Aircenter SX 3/7.5
SIGMA CONTROL BASIC
Number: 9_6945 01USE
manroland document no.:
80.95A0S–C338
2
Table of Contents
Default Chapter
3
Table of Contents
3
1 Regarding this Document Using the Document
11
Additional Documents
11
Copyright
11
Symbols and Identification
11
Warnings
11
Other Instructions and Symbols
12
Tab. 1 the Levels of Danger and Their Meaning
12
2 Technical Data Nameplate
13
Options
13
Tab. 2 Nameplate
13
Weight
14
Temperature
14
Ambient Conditions
14
Tab. 3 Options
14
Tab. 4 Machine Weight
14
Tab. 5 Temperature
14
Tab. 6 Ambient Conditions
14
Ventilation
15
Pressure
15
Air Receiver
15
Fig. 1 Maximum Relative Humidity
15
Tab. 7 Ventilation
15
Tab. 8 Safety Relief Valve Activating Pressure
15
Tab. 9 Air Receiver: Volume
15
Free Air Delivery
16
Sound Pressure Level
16
Tab. 10 Safety Relief Valve: Activating Pressure
16
Tab. 11 Free Air Delivery
16
Tab. 12 Sound Pressure Level
16
Motors and Power
17
Compressor Drive Motor
17
Cooling Oil Recommendation
17
Basic Information
17
KAESER Lubricants
17
Tab. 13 Compressor Drive Motor
17
Cooling Oil Volume
18
Power Supply
18
Tab. 14 Cooling Oil Charge
18
Power Supply Specifications
19
Fig. 2 Three-Phase Star (Wye); 4 Wire; Grounded Neutral
19
Fig. 3 Three-Phase Star (Wye); 3 Wire; Grounded Neutral
19
Tab. 15 Connection Data
19
Tab. 16 Connection Data
19
Refrigeration Dryer
20
Tab. 17 Refrigeration Dryer: Model
20
Tab. 18 Refrigeration Dryer: Compressed Air System
20
Tab. 19 Refrigeration Dryer: Refrigerant Circuit
20
3 Safety and Responsibility Basic Information
21
Specified Use
21
Improper Use
21
User's Responsibilities
21
Observe Statutory and Universally Accepted Regulations
21
Qualified Personnel
22
Adherence to Inspection Schedules and Accident Prevention Regulations
22
Dangers
22
Safely Dealing with Sources of Danger
23
Safe Machine Operation
25
Organizational Measures
25
Danger Areas
25
Safety Devices
26
Safety Signs
26
Fig. 4 Location of Safety Signs
26
Tab. 20 Danger Areas
26
In Emergency
28
Fire Fighting
28
Remove any Compressor Cooling Oil from Your Person
28
Injury from Handling Refrigerant
28
Tab. 21 Safety Signs
28
Warranty
29
Environmental Protection
29
4 Design and Function
30
Housing
30
Fig. 5 Enclosure
30
Function
31
Fig. 6 Machine Layout
31
Refrigeration Dryer
32
Air Receiver
32
Floating Relay Contacts
32
Fig. 7 Refrigeration Dryer
32
Fig. 8 Air Receiver
32
Options
33
Machine Mountings
33
LOAD-IDLE Control by Remote Contact
33
Fig. 9 Machine Mountings
33
Microfilter
34
Activated Carbon Filter
34
Fig. 10 Microfilter
34
Fig. 11 Activated Carbon Filter
34
Operating Modes and Control Modes
35
Operating Modes
35
Control Modes
35
Refrigeration Dryer Control Modes
36
Tab. 22 Operating States under MODULATING Control
36
Safety Devices
37
SIGMA CONTROL BASIC Keys and Indicators
37
Fig. 12 Keys
37
Tab. 23 Refrigeration Dryer Control Modes
37
SIGMA CONTROL BASIC Function
38
Display Layout
38
Fig. 13 Indicators
38
Tab. 24 Keys
38
Tab. 25 Indicators
38
Parameters
39
Tab. 26 Display
39
Messages
40
Tab. 27 Parameters
40
5 Installation and Operating Conditions
41
Safety
41
Installation Conditions
41
Determining Location and Clearances
41
Ensure Adequate Ventilation
42
Exhaust Duct Design
42
Fig. 14 Recommended Machine Placement and Dimensions [In]
42
Using the Compressor to Supply a Compressed Air System
43
6 Installation Safety
44
Reporting Transport Damage
44
Making the Compressed Air Connection
44
Making the Power Supply Connection
45
Fig. 15 Compressed Air Connection
45
Refrigeration Dryer: Connecting the Transformer According to the Power Supply
46
Connecting the Condensate Drain
46
Fig. 16 Condensate Drain Dimensions [Inch]
46
Options
47
Anchoring the Machine
47
Connecting the Remote Contact LOAD-IDLE Control
47
Fig. 17 Connections to SIGMA CONTROL BASIC
47
7 Initial Start-Up Safety
48
To be Noted before Commissioning
48
Checking Positioning and Operating Conditions
49
Tab. 28 Re-Commissioning after Storage
49
Tab. 29 Positioning and Operating Conditions Checklist
49
Setting the Overload Protection Cut-Out
50
Hot Gas Bypass Valve Setting
50
Fig. 18 Hot Gas Bypass Valve Adjustment for Altitude
51
Fig. 19 Adjustment Angle
51
Pouring Cooling Oil into the Airend
52
Fig. 20 Inlet Valve Filling Port
52
Tab. 30 Altitude Correction
52
Checking Direction of Rotation
53
Starting the Machine for the First Time
53
Checking the Door Interlock Switch
54
Setting the Setpoint Pressure
54
Fig. 21 Interlock Switch Position
54
8 Operation
56
Switching on and off
56
Switching on
56
Switching off
56
Fig. 22 Switching on and off
56
Switching off in an Emergency and Switching on Again
57
Fig. 23 Switching off in an Emergency
57
Tab. 31 Switching off With/Without Run-On Time
57
Acknowledging Alarm and Warning Messages
58
Setting Parameters
58
Fig. 24 Acknowledging Messages
58
9 Fault Recognition and Rectification
60
Alarm Messages (Machine Stop)
60
Basic Information
60
Tab. 32 Alarm Messages
61
Tab. 33 Warning Messages
61
Warning Messages
61
Other Faults
62
Tab. 34 Other Faults and Actions
62
10 1 Maintenance
63
Safety
63
Maintenance Schedule
63
Logging Maintenance Work
63
Resetting Maintenance Interval Counters
64
Regular Maintenance Tasks
64
Cooling Oil Changing Interval
65
Regular Service Work
66
Cooler: Cleaning or Renewing the Filter Mats
66
Fig. 25 Filter Mat for the Air and Oil Cooler
66
Tab. 37 Regular Service Work
66
Cleaning or Replacing the Control Cabinet Filter Mats
67
Cooler Maintenance
67
Fig. 26 Control Cabinet Ventilation Grill
67
Air Filter Maintenance
68
Fig. 27 Filter Mat for Air and Oil Cooler
68
Drive Motor Maintenance
69
Maintaining the Drive Belts
69
Fig. 28 Air Filter Maintenance
69
Pressure Relief Valve Checking
70
Fig. 29 Changing the Belt
70
Checking the Overheating Safety Shutdown Function
72
Checking the Cooling Oil Level
72
Venting the Machine (Depressurizing)
72
Fig. 30 Checking the Cooling Oil Level
72
Tab. 38 Permissible Cooling Oil Level under LOAD
72
Fig. 31 Venting the Machine
73
Topping up the Cooling Oil
74
Venting the Machine (Depressurizing)
75
Fig. 32 Topping up the Cooling Oil
75
Top up with Cooling Oil and Test Run
76
Changing the Cooling Oil
77
Fig. 33 Changing the Cooling Oil, Oil Separator Tank
77
Changing the Oil Filter
79
Fig. 34 Changing the Cooling Oil, Oil Cooler
79
Fig. 35 Changing the Oil Filter
80
Changing the Oil Separator Cartridge
81
Fig. 36 Changing the Oil Separator Cartridge
81
Refrigeration Dryer Maintenance
82
Cleaning the Refrigerant Condenser
82
Fig. 37 Refrigeration Dryer
82
Checking Condensate Drainage
83
Condensate Drain Maintenance
83
Fig. 38 Checking Condensate Drainage
83
Fig. 39 Condensate Drain Maintenance
84
Service Air Receiver
85
Drain Condensate Manually
85
Checking the Safety Relief Valve
85
Fig. 40 Condensate Drain Tap
85
Fig. 41 Testing the Safety Relief Valve
85
Document Maintenance and Service Work
86
Tab. 39 Logged Maintenance Tasks
86
11 Spares, Operating Materials, Service
87
Note the Nameplate
87
Ordering Consumable Parts and Operating Fluids/Materials
87
Kaeser Air Service
88
Service Addresses
88
Spare Parts for Service and Repair
88
Tab. 40 Consumable Parts
88
12 Decommissioning, Storage and Transport
91
Putting out of Operation
91
Packing
91
Storage
91
Transporting
92
Safety
92
Transporting with a Forklift
92
Transporting with a Crane
92
Fig. 42 Transporting with a Forklift
92
Disposal
93
Fig. 43 Transporting with a Crane
93
13 Annex
94
Pipeline and Instrument Flow Diagram (P+I Diagram)
94
Pipe and Instrument Flow Diagram (P+I Diagram): MODULATING Control Mode
100
Dimensional Drawing
106
Electrical Diagram
108
Service Manual for Compressed Air Filter
125
5
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KAESER Aircenter SX 7.5 Specifications
General
Type
Rotary Screw Compressor
Power
7.5 kW
Max Pressure
11 bar
Voltage
400 V
Model
Aircenter SX 7.5
Air receiver capacity
270 l
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