KAESER ESD.2C - Page 37

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Service Manual

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://www.kaeser.com

Main Page

Table of Contents1
Technical Documentation2
Wiring Diagram5
General7
Electrical Equipment Identification8
General Components8
Sensors/Actuators8
Terminal Strips/Plug-In Connections8
Compressor Control9
Power Unit Frequency Converter9
Performance-Related Components10
Contents39
List of Illustrations43
Table of Contents43
List of Tables45
Symbols and Labels47
Tab. 1 Danger Levels and Their Definition (Personal Injury)47
- Warnings47
- Other Alerts and Their Symbols48
- Potential Damage Warnings48
- Tab. 2 Danger Levels and Their Definition (Damage to Property)48
- Tab. 3 Nameplate50
- Tab. 4 Options50
  - Technical Specifications50
  - Weight50
- Tab. 5 Machine Weight51
- Tab. 6 Temperature51
- Tab. 7 Ambient Conditions51
- Tab. 9 Ambient Conditions51
  - Ventilation51
  - Mass Flow Rate52
  - Pressure52
- Tab. 8 Ventilation52
- Cooling Oil53
- Fig. 1 Mass Flow Rate and Regulating Range53
- Tab. 10 Mass Flow Rate and Regulating Range53
- Tab. 11 Mass Flow Rate53
- Motors and Power54
- Tab. 12 Cooling Oil Recommendation54
- Tab. 13 Cooling Oil Charge54
- Tab. 14 Compressor Drive Motor54
  - Basic Requirements55
  - Power Supply55
- Tab. 15 Fan Motor (Option K1)55
- Tab. 16 Fan Motor (Option K2/K9)55
- Tab. 17 Noise Emission [Db(A)]55
- Fig. 2 Correct Use of RCD56
  - Further Requirements56
  - Grounded Conductor Specification56
  - Power Supply Specifications56
  - Closed Cooling System57
  - Open Cooling System57
- Tab. 18 Connection Data57
  - Water Cooling57
  - Cooling Water Quality58
  - Design Data58
- Tab. 19 Cooling Water Temperature (ΔT=10K)58
- Tab. 20 Specification: Heat Exchanger (Option K2)58
  - Water Cooling (Plate-Type Heat Exchanger)58
  - Cooling Water Temperature Rise 15 K59
- Tab. 21 Cooling Water Quality59
- Tab. 22 Cooling Water Temperature (ΔT=10K)59
- Water Cooling (Bundled Pipe Heat Exchanger)59
- Tab. 23 Specification: Heat Exchanger (Option K9)60
- Tab. 24 Cooling Water Quality60
  - Improper Use61
  - Safety and Responsibility61
  - Specified Use61
  - User's Responsibilities61
  - Adherence to Inspection Schedules and Accident Prevention Regulations62
  - Defining Personnel62
  - Dangers63
  - Electricity63
  - Forces of Compression63
  - Safely Dealing with Sources of Danger63
- Tab. 25 Inspection Intervals According to Ordinance on Industrial Safety and Health63
  - Operating Fluids/Materials64
  - Rotating Components64
  - Unsuitable Spare Parts64
  - Conversion or Modification of the Machine65
  - Personal Protective Equipment65
  - Safe Machine Operation65
  - Transporting65
  - Commissioning, Operation and Maintenance66
  - Decommissioning, Storage, Disposal67
  - Organisational Measures67
  - Safety Devices67
- Tab. 26 Danger Areas67
- Fig. 3 Location of Safety Signs68
  - Correct Fire Fighting69
  - In Emergency69
- Tab. 27 Safety Signs69
  - Extinguishing Substances70
  - Treating Injuries from Handling Cooling Oil70
  - Environment Protection71
  - Design and Function72
- Fig. 4 Enclosure Overview72
- Function Description72
- Fig. 5 Machine Layout73
  - Floating Relay Contacts73
  - Frequency Converter73
- Fig. 6 Machine Mountings74
- Fig. 7 Cooling Air Filter Mat (Option K3)74
  - Operating Modes75
  - Variable Speed with Frequency Converter (SFC)75
- Fig. 8 Keys - Overview76
- Operating Panel SIGMA CONTROL 276
- Tab. 28 Keys76
- Indicators - Overview77
- Tab. 29 Indicators77
- Typical Application78
Fig. 10 RFID Sensor Field78
- Tab. 30 RFID Sensor Field78
- Complying with Safety Notes79
- Ensuring Safety79
- Installation and Operating Conditions79
- Installation Conditions79
- Ensuring the Machine Room Ventilation80
Fig. 11 Recommended Machine Placement and Dimensions [MM]80
- Exhaust Duct Design81
- Gas Inlet Side81
- High Pressure Side81
- Operating the Machine in a Compressed Gas Network81
- Oil Return Line82
- Checking the Tightness84
Fig. 12 Gas Connection84
- Installing Gas Connections84
- Reporting Transport Damage84
- When Working on the Drive System84
- Connecting the Power Supply85
- Anchoring the Machine86
- Connecting the External Pressure Transducer86
Fig. 13 Connecting the Cooling Water87
- Initial Start-Up88
- When Working on Live Components88
- When Working on the Compressed Air System88
- Checking Installation and Operating Conditions89
- Special Measures for Re-Commissioning after Storage89
- Tab. 31 Re-Commissioning after Storage89
  - Commissioning the Frequency Converter90
  - Filling Cooling Oil into the Airend90
- Tab. 32 Installation Conditions Checklist90
Filling with Cooling Oil90
Fig. 14 Inlet Valve Oil Filling Port91
Fig. 15 Coupling91
- Evacuating the Machine92
- Filling with Gas92
- Setting the Motor Overload Protection Switch92
- Starting the Machine for the First Time92
- Checking the Direction of Rotation93
- Setting the Display Language93
Fig. 16 Switching on and off94
- Operation94
- Switching off in an Emergency and Switching on Again95
- Switching on and off from a Remote Control Centre95
Fig. 18 Switching on and off from a Remote Control Centre96
- Tab. 34 Remote Control Identification96
- Machine Identification96
- Switching on and off with the Clock96
- Acknowledging Alarm and Warning Messages97
Fig. 19 Switching on and off with the Clock97
- Interpreting Operation Messages97
- Alarm Message98
Fig. 20 Acknowledging Messages98
- Fault Recognition and Rectification99
- Other Faults99
- Tab. 36 Other Faults and Actions100
- Maintenance101
- Tab. 37 Advise Others that the Machine Is Being Serviced101
- Following the Maintenance Plan102
- Linde Regulations102
- Logging Maintenance Work102
- Regular Maintenance Tasks103
- Resetting Maintenance Interval Counters103
- Check the Oil Collecting Tank104
Fig. 21 Cooling Oil Collecting Tank104
- Tab. 39 Regular Service Tasks104
- Control Cabinet: Clean or Renew the Filter Mat105
- Cooler Maintenance105
Fig. 22 Switching Cabinet Ventilation105
Fig. 23 Cleaning the Cooler106
- Water-Cooling Maintenance106
- Checking for Leaks107
- Cleaning or Renewing the Cooling Air Filter Mat107
Fig. 24 Cooling Air Filter Mat107
Cleaning Cloths108
Fig. 25 Compressor Motor Maintenance108
- Checking the Coupling109
- Motor Running109
- Checking the Pressure Relief Valve110
Fig. 26 Checking the Coupling110
- Checking the Cooling Oil Level111
- Checking the Overheating Safety Shutdown Function111
Fig. 27 Checking the Cooling Oil Level112
Venting the Machine (De-Pressurising)112
Fig. 28 Venting the Machine113
- Vent Gas Manually from the Gas Cooler113
- Vent the Oil Separator Tank113
Fig. 29 Replenishing the Cooling Oil114
- Topping up with Cooling Oil and Trial Run115
- Changing the Cooling Oil116
- Cooling Oil Receptacle116
- Draining the Oil from the Separator Tank117
Fig. 30 Changing the Cooling Oil, Oil Separator Tank117
Draining the Oil from the Cooler118
Fig. 31 Changing the Cooling Oil, Oil Cooler118
Draining the Oil from the Airend119
Fig. 32 Changing the Cooling Oil, Airend119
Starting the Machine and Performing a Trial Run119
Fig. 33 Changing the Oil Filter120
Changing the Oil Separator Cartridge121
Fig. 34 Open the Enclosure (Oil Separator Cartridge Changing)122
Fig. 35 Changing the Oil Separator Cartridge122
Opening the Machine Enclosure122
Fig. 36 Open the Enclosure (Oil Separator Cartridge Changing)123
Dimensions of the Flexible Pipe Connection124
Fig. 37 Assembling Flexible Pipe Connections124
- Documenting Maintenance and Service Work125
- Tab. 41 Logged Maintenance Tasks125
  - Note the Nameplate126
  - Ordering Consumable Parts and Operating Fluids/Materials126
- Tab. 42 Consumable Parts126
- Spares, Operating Materials, Service126
- Decommissioning, Storage and Transport128
- Packing128
- Putting out of Operation128
- Putting out of Operation for a Longer Period128
Fig. 38 Transport with a Forklift Truck129
Disposal130
Fig. 39 Transport with a Crane130
- Pipeline and Instrument Flow Diagram (P&I Diagram)131
- Dimensional Drawing134
- Electrical Diagram142
- Important Settings176
- Optimizing the Brightness Settings177
- Optimizing the Contrast Settings177
- Setting the Contrast and the Brightness177
- KAESER Equipment Card179
- Log on with Equipment Card179
- Logging on with Equipment Card179
- RFID Reader180
- Adjusting the System Setpoint Pressure181
- Activating the «Clock» Key182
- Check Box Status182
- Entering Switching Points182
- Activating/Deactivating the Check Box185
- Changing the Control Mode188
- Assigning a Message to an Output189
- Maintenance Menu190
- Performing the Test192
- Safety Relief Valve Checking192
- Correct Conclusion of the Test193
- Interpreting Diagnostic Messages200
- Interpreting Fault Messages201
- Interpreting Warning Messages207
- Interpreting System Messages211
- Fig. 9 Indicators - Overview216
Fig. 17 Switching off in an Emergency216
- Tab. 33 Machine Identification218
- Tab. 35 Machine Identification218
  - SIGMA CONTROL 2 Controller223
  - Technical Data223
  - User Interface with Display, CPU and Interfaces223
  - Identification with RFID Equipment Card224
  - Input/Output Modules224
  - Cable Lengths226
  - Degree of Protection, IOM226
  - IOM Dimensions226
  - Maximum Cable Lengths226
  - Resistance Thermometer227
  - Basic Instructions228
  - Main Control System (MCS)229
  - System Structure229
  - The Controller229
  - Operating Panel230
  - Header233
  - Lines 7 and 8: Machine State233
  - Active Line234
  - Main Menu234
  - Setting Parameters234
  - Access Rights235
  - Activating Keys with Check Boxes235
  - Resetting Current Parameters235
  - Checking the Machine Status with KAESER CONNECT236
  - KAESER CONNECT for SIGMA CONTROL 2236
  - Secure Storage of the RFID Equipment Cards236
  - Menus – Overview237
  - Menu Structure238
  - Status Menu241
  - Menu: Power Switching249
  - Operating Modes and Control Modes249
  - Control Modes250
  - Continuous251
  - Frequency-Controlled Drive (SFC)251
  - Quadro251
  - Vario251
  - MODULATING Control252
  - Maintaining Ambient Conditions253
  - Configuring the Controller255
  - Selecting Menu Options255
  - Changing the Display Language256
  - Display Language256
  - Back of the KAESER Equipment Card257
  - Generating a Password for the SIGMA CONTROL 2257
  - Noting the Number of the KAESER Equipment Card257
- Controlling Access to the SIGMA CONTROL 2 Via Manual Input259
- Checking/Setting the Time and Date261
- Generating a Password for KAESER CONNECT261
- Checking/Setting the Date262
- Setting Display Formats263
  - Setting the Time Format263
  - Time Formats263
  - Units of Pressure264
  - Display Illumination265
  - Setting the Display Illumination265
- Setting and Activating Summer/Winter Time266
- Using KAESER CONNECT266
- Calling up KAESER CONNECT for SIGMA CONTROL 2267
- Displaying the System Status268
- Display Graphs270
  - Arrow Keys271
  - Pressure/Temperature Graphs271
  - Zoom and Arrow Key Functions271
  - Arrow Keys and Functions272
- Displaying Messages272
- Creating Additional User Accounts273
- Viewing the IO Modules Assigment273
  - "Log on for Write Access" Window274
  - User Administration Menu274
  - Creating a New User275
  - Updating User Accounts275
- Settings276
- Closing KAESER CONNECT277
- Performing a Data Backup277
- Adjusting the Pressure Parameters of the Machine278
- Displaying Pressure Parameters279
  - Opening the Menu for Pressure Parameters279
  - Adjusting the System Setpoint Pressure: Pa and Pb280
- Configuring the Pressure Parameters for Compressors280
  - Displaying Compressor Parameters280
  - Adjusting Pressure Rise Pe281
  - Adjusting the Value for “System Pressure Low”281
  - Adjusting Pressure Rise: Machine with Variable Frequency Drive (SFC)282
  - Pressure Rise in Frequency-Controlled (SFC) Machines282
  - Activating/Deactivating the «LOAD/IDLE» Key283
- Automatic Start/Stop in Programmed Clock Mode284
- Configuring Machine Start and Stop284
  - Selecting the Compressor Clock Menu284
  - Example of a Machine ON/OFF Timer Program285
  - Setting the Clock Program (Example)285
  - Activating the «Compressor Timer» Key287
- Setting up the Holiday Period287
- Starting the Machine Remotely (Remote ON/OFF)288
  - Switch Machine Start to Remote Mode288
  - Activating/Deactivating the «Remote Control» Key289
  - Assigning Another Input290
- Activating/Deactivating the Idle Phase (Venting Period Function)291
- Activating/Deactivating and Adjusting the "Automatic Restart after a Power292
- Activating and Adjusting the Control Modes293
- Selecting a Control Mode294
- Adjusting the Idle Time of DUAL Mode295
- Adjusting the Minimum Running and Unloaded Period in QUADRO Control295
- Activating the Settings for the Refrigerated Dryer296
- Setting the CLOCK Mode297
- Output Messages298
- Fault in the Refrigerated Dryer – Activate Fault Mode299
- Configuring the Machine for Local Mode301
- Configuring the System Pressure Setpoint Changeover Using the Clock Program301
- Local Operating Mode (Local Mode)301
- Selecting the < Configuration ➙ Pressure Control ➙ Load Control > Menu301
  - Example of System Pressure Changeover Switching Points302
  - Deleting the Existing Clock Program303
- Configuring the System Pressure Setpoint Changeover Using the Clock304
  - Selecting the Operating Mode304
  - Setting Clock Periods Pa and Pb304
  - Selecting Local Mode305
  - Setting Starting Time for Pa or Pb305
- Configuring the Machine for Master Control306
- List of the Various Master Controllers306
- Configuring Profibus Mode (SIGMA AIR MANAGER or VESIS)307
  - Master Control – Overview307
  - Profibus DP-V0 Retrofit Kit Required307
  - Profibus Plug Wiring308
  - Wiring the Interface Plug308
  - Inserting the Communication Module310
  - Communication Interface311
  - Inserting and Fixing the Communication Module311
  - Proper Removal of the Plastic Cover311
  - Activating Operation Via Profibus312
  - Front Plate of the PROFIBUS Communication Module312
  - Setting the Reaction for a Bus Fault313
  - Activate the Communications Module314
  - Activate the «Remote Control» Key315
- Configuring the Profibus Interface Without SIGMA AIR MANAGER or VESIS316
- Selecting the Profibus Interface316
- (Ethernet Interface)317
- Assigning the Slave Address317
- Configuring for Master Control of Two Machines in Master/Slave Operation317
  - Establishing the Electrical Connection318
  - Master-Slave Configuration Procedure318
  - Configuring the Controller of Machine 1 as Master319
  - Connecting the Ethernet Cable with the Machine319
  - Direct Connection of Two SIGMA CONTROL 2319
  - Installing the Ethernet Cable319
  - Deactivating the «Remote Control» Key320
  - Set the Switching Points Pa and Pb320
  - Setting the Times320
  - IP Configuration321
  - Activating the «Remote Control» Key322
  - Configuring the Controller of Machine 2 as Slave322
  - Setting the Remote Operating Mode322
- Configuring for Master Control Using the LOAD Remote Contact323
- Sigma Air Manager Basic)323
  - Making the Electrical Connection for Remote LOAD Contact324
  - Adjusting Pressure Increase Pe325
  - Assigning the Input for LOAD Remote Contact325
- Configuring for Master Control with Local/Load Remote Contact326
  - Making the Electrical Connection326
  - Set Local/Load Remote Contact Operating Mode327
  - Setting Local Operating Mode Pb327
  - Setting the LOAD Remote Contact Operating Mode and Assigning the Input328
- Configuring Setpoint Pressure Pre-Selection Via Remote Contact329
  - Setting the LOAD Remote Contact Operating Mode329
  - Assigning the Remote Contact Input330
  - Setting up Remote Contact Mode Pa/Pb330
- Configuring Master Control of Compressors Regulated by Pressure Switch331
  - Configuring Master Control Via Floating Relay Contact331
  - Machine with Pressure Switch Regulation332
  - Assigning the Floating Relay Contact (Activate)333
  - Configuring Local Mode333
  - Configuring the Master Control Without an Electrical Connection334
  - Configuring the Clock Program336
  - Example Switching Points336
  - Set the Time for the First Two Switching Points337
  - Setting Local Mode338
- Examples of Time Settings for Equal Overall Load339
- Configuring Email340
  - Example for a Clock Program for Equal Duty Cycling During the Day340
  - Example for a Clock Program for Equal Duty Cycling During the Week340
  - Configure and Activate the Email Function341
- Configuring Input and Output Signals342
- Assigned Output Signals343
- Outputting Important Operational States of the Machine343
- Displaying Analog Input Values344
  - Selecting the Analog Data Menu345
  - Assigning the Analog Input346
  - Editing Sensor Designation and Unit of Measure346
  - Assigning a Value Range to the Measurement Signal (Calibration)347
  - Determining the Type of Current Signal (0/4–20 Ma)347
- Displaying Additional Binary Input Signals348
  - Assign and Activate the Input349
  - Entering the Message Text349
  - Setting the Time Delay350
  - Assign and Activate the Output351
  - Setting the Logic351
- Activating Remote Acknowledgement352
- Selecting the Message Type (Operational, Alarm, Warning)352
- Activating the "Remote Control" Key353
- Selecting the < Configuration ➙ Acknowledgement > Menu353
- Setting the Remote Acknowledgement Function353
- Assigning an Input354
- Linking to an External Pressure Transducer355
- Transmission of Sensor Value355
- Assigning an Input to an External Sensor356
- Selecting the < Configuration ➙ Pressure Control > Menu356
- Checklist of Installation Conditions357
- Commissioning the Machine357
- Operation359
- Switching off359
- Switching on359
- Switching on and off359
- Acknowledging Alarm and Warning Messages360
- Switching off in an Emergency and Switching on Again360
- Displaying Messages362
  - Information of a Message362
  - Message Type and Status Abbreviations362
  - Displaying the Last Fault/Warning363
  - Displaying the Message History363
- Selecting the Status Menu363
- Displaying the Current Operating Mode364
  - Operating Mode Display364
  - Abbreviation of Operating Modes365
- Adjusting Working Pressure365
- Possible Operating Modes365
- Displaying Analog Data366
- Displaying Operating Data367
- Interpreting Operation Messages368
- Setting the Maintenance Interval370
- Preparing the Test371
- Safety Relief Valve Checking371
- Checking the Temperature Sensor and Overheating Shutdown Function373
- Basic Instructions376
- Fault Recognition and Rectification376
- Interpreting Alarm Messages376
- Interpreting Diagnostic Messages381
- Interpreting System Messages381
- Interpreting Warning Messages381
- 10 Maintenance386
- Maintenance Work386
- 11 Spares, Operating Materials, Service387
- Displaying the Version Number, Machine Model, Part Number and Serial Number387
- Kaeser Air Service387
- Note the Nameplate387
- Service Addresses387
- 12 Decommissioning, Storage and Transport389
- Commissioning389
- Disposal389
- Packing389
- Storage389
- Transporting389
- Spare Parts391
- Machine Data401
- Spares for Service and Repair401
- ESD 442 SFC / 14 Bar403

KAESER ESD.2C - Page 37

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