Make sure you give the data from the nameplate. Copyright This service manual is copyright protected. Please contact KAESER if you have any queries regarding the use and duplication of this documentation. We will gladly help you in the ap- propriate use of the information.
Regarding this Document 1.4.2 Other notices and symbols This symbol indicates a task to be carried out. This symbol identifies environmental protection measures. This symbol indicates particularly important information. 1 --- 2...
Technical Specification Technical Specification Model designation and important technical information is found on the machine’s name- plate. The nameplate is located on the outside of the machine: above the cooler, or on the rear of the machine. Please enter here the data from the nameplate: ¡...
Technical Specification Supply frequency 60 Hz Maximum working pressure Maximum working pressure Delivery [m /min] [bar] [bar] CSD 82 CSD 102 CSD 122 10.0 12.0 Tab. 8 Delivery (60 Hz) Sound Pressure Level Operational state under load at rated speed, rated delivery and rated pressure. Measuring conditions: Free---field measurement to CAGI/PNEUROP PN8 NTC 2.3 at 1 m distance CSD 82...
It is imperative that measures for cooling water treatment and filtration are carried out. The addresses of companies specialising in cooling water analysis and the supply of suit- able equipment for its treatment can be obtained from KAESER. To avoid operational breakdowns caused by a corroded or clogged cooler, the cooling...
Safety and Responsibility Safety and Responsibility Disregard of these instructions can result in serious injury. DANGER Read the service manual carefully and take notice of the contents for safe machine operation. The machine is manufactured to the latest engineering standards and acknowledged safety regulations.
Safety and Responsibility These are people who, by virtue of their training, knowledge and experience as well as their knowledge of the prevailing conditions, can assess the work to be done and recogn- ise the possible dangers involved. Operating personnel Authorised operating personnel: must be of legal age, must be conversant with and adhere to the safety instructions and sections of the ser-...
Safety and Responsibility Safety Devices Do not change, bypass or disable safety devices. Do not remove or obliterate labels and notices. Ensure that labels and notices are clearly legible. More information on safety devices is contained in chapter 4 ’Design and Function’, sec- tion 4.4 ’Safety Devices’.
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Use only spare parts approved by the manufacturer for use in this machine. Unsuit- able spare parts compromise the safety of the machine. Use only genuine KAESER parts for pressure components. Conversion or modification of the machine Do not permit conversion or modification of the machine as this can compromise func- tion and safe working.
Safety and Responsibility Extension or modification of the compressed air station If a compressed air installation is to be extended or modified, check the blow ---off ca- pacity of the pressure relief valves on air receivers and pipelines before installing the new machines.
Safety and Responsibility Carry out regular inspections: ¡ for damage, ¡ of the safety devices, ¡ of the EMERGENCY STOP function, ¡ of components needing to be monitored. Machines drawing in air from the surroundings should not be operate without an air filter.
Safety and Responsibility Safety Devices Do not change, bypass or disable safety devices. Do not remove or obliterate labels and notices. Ensure that labels and notices are clearly legible. More information on safety devices is contained in chapter 4 ’Design and Function’, sec- tion 4.4 ’Safety Devices’.
Safety and Responsibility Loca- Sign Meaning tion Serious injury, particularly to the eyes, can result from foreign objects being thrown back from rotating components. Do not allow foreign objects to fall through the ventilation grille Do not work above the ventilation grille when the machine is running Wrong cooling oil level Machine damage or excessive oil remaining the compressed air.
Safety and Responsibility Environmental Protection Do not allow cooling oil to escape to the environment or into the sewage system. Store and dispose of operating materials and replaced parts in accordance with local envi- ronment protection regulations. Observe national regulations. This applies particularly to parts contaminated with cooling oil.
Design and Function Design and Function Machine Overview 4.1.1 Cabinet Fig. 2 Cabinet Control cabinet door Latch Removable panel The cabinet, when closed, serves various purposes: Sound damping Protection Cooling air flow control Safe and reliable operation can only be ensured with the cabinet closed. Latches are released by a key supplied with the machine.
Design and Function 4.1.2 Function An air–cooled machine serves to illustrate function. Fig. 3 Air ---cooled machine Inlet valve Control cabinet Minimum pressure/check valve Oil separator tank Compressor motor Air filter Oil filter Oil / air cooler Airend Machine Ambient air is cleaned as it is drawn in through the filter (8). The air is then compressed in the airend (5).
Design and Function Options 4.2.1 Machine mountings (option H1) The machine mountings enable the machine to be anchored to the floor. 4.2.2 Cooling air filter mats (option K3) Mats filter the cooling air and keep the cooler surface clean. Fig. 4 Cooling air filter mats Cooling air filter mat 4.2.3...
The load and power consumption of the drive motor rises and falls with the air de- mand. The regulating valve is factory set. Consult with KAESER Service before changing. 4.3.2 Tasks of the controller Using the selected control mode, the controller switches the compressor between its vari- ous operational states in order to maintain system pressure between the set minimum and maximum values.
Design and Function When the maximum pressure is reached the machine switches to idle running. When the preset idling time has elapsed the machine is STOPPED. The shorter the idling time setting, the sooner and more frequently the motor is stopped. VARIO The VARIO control mode is an extension of DUAL control.
Design and Function SIGMA CONTROL Keys and Indicators Fig. 7 SIGMA CONTROL keys Symbol Item Description Function ON (I) Switch the machine on. Programmed operating mode is active. OFF (0) Switch the machine off. Operating mode: Switching clock ---control on and off. Clock The LED lights when the machine is under clock control.
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Design and Function Symbol Item Description Function Events and infor- Displays the event memory. mation key Selection from every menu. Returns together with ’esc’ key (8). Acknowledge (re- Acknowledges (re---sets) messages and resets the set) key event memory (if permitted). Tab.
The spacings given are recommended and ensure unhindered access to all machine parts. Please consult KAESER if they cannot be achieved. If installed outdoors, the equipment must be protected from frost, direct sunlight, dust and rain. Ensure accessibility so that all work on the machine can be carried out without danger or hindrance.
Installation and Operating Conditions Fig. 9 Installation recommendation, dimensions [mm] Exhaust fan Exhaust air duct Inlet air opening 5.2.2 Ventilation Values given are minimum guidelines. If the inlet aperture is insufficient a dangerous vacuum can be created in the compressor room. Ensure that the volume of air flowing into the compressor room is at least equivalent to that being removed from it by the compressor and exhaust fan.
These conditions are detrimental to correct air treatment. Air quality suffers. To ensure maintenance of desired air quality when filling a vented air main we recommend the installation of an air main charging system. KAESER is ready to offer good advice. 5 --- 30...
Installation Installation Safety Voltage! There is danger of fatal injury caused by touching electrically live compo- DANGER nents. Isolate all phases of the main power supply. (switch off the mains supply disconnecting device) Ensure that the power supply cannot be switched on again (locked off).
Installation Shut ---off valve (2) to be installed by the user in the connection line. Make the compressed air connection with a flexible hose (1) or an axial compensa- tor (1). Electrical Connection Have the electrical connection made only by a qualified and authorised electrician. Carry out protection measures as stipulated in relevant regulations (IEC 364 or DIN VDE 0100, for example) and in national accident prevention regulations (BGV A2 in Ger- many).
Installation Connect the machine to the mains power supply in accordance with Fig. 12 and the electrical diagram in chapter 13.1.4. Fig. 12 Electrical Connection User ---provided main switch and fusing Options 6.5.1 Machine fixing (option H1) If the machine is supplied with mountings, these can be used to anchor it to the floor. De- tails of the fixing holes are contained in the dimensional drawing in chapter 13.1.3.
Installation Fig. 13 Water cooling connection Cooling water outlet 10 Shut ---off valve Cooling water inlet 12 Connection port with stopper 17 Pressure relief valve The user is to provide the following fittings: Dirt trap with max. 0.1 mm strainer mesh. Shut ---off valves (10) and connection ports (12) for maintenance and venting.
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Installation Fig. 14 Heat recovery Outlet 10 Shut ---off valve Inlet 12 Connection port with stopper 17 Pressure relief valve The user is to provide the following fittings: Dirt trap with max. 0.1 mm strainer mesh. Shut ---off valves (10) and connection ports (12) for maintenance and venting. Pressure relief valve (17) on the inlet (B) prevents build ---up of excessive pressure.
Change the oil separator cartridge. Change the cooling oil. Have the motor bearings checked by an authorised KAESER service agent. 36 months Have the overall technical condition checked by an autho- rised KAESER service agent. Tab. 36 Re ---starting after storage 7 --- 36...
Initial Start--- up Checking Installation and Operating Conditions Carry out all the items in the checklist before starting the machine. To be checked Chapter Done? Are all the conditions for installation fulfilled? User’s lockable supply disconnecting device installed? Is the power supply as specified on the nameplate? Supply cable section and fuse rating adequate? 2.9.2 All electrical connections checked for tightness?
Initial Start--- up Use the same type of oil. A sticker giving the type of oil used is found near the oil separator tank filling port. Fig. 15 Inlet valve oil filling port Screw plug Inlet valve Remove the plug (1) from the inlet valve (2). Pour cooling oil into the airend.
Initial Start--- up Initial Start---up Open the shut ---off valve to the air network. Switch on at the main supply isolator. The controller makes a self---test and the green LED ’Power ON’ lights. Press the ’Operating state LOAD/IDLE’ key. Press the ’ON’ key. The green LED ’Machine ON’...
Operation Operation Fig. 17 Switching on and off ’Machine ON’ LED (green) ’Remote’ key ’ON’ key (’I’) ’LOAD’ LED OFF key (’0’) ’IDLE’LED ’Clock’ key ’Power ON’ LED (green) LOAD/IDLE toggle key Switching on and off Compressed air! WARNING Serious injury is possible. Never direct compressed air at persons or animals.
Operation 8.1.3 Switching off Press the ’LOAD/IDLE’ toggle key (13). The machine switches to IDLE and the LED (7) flashes. After running in idle for 20 seconds, press the OFF key (3). The ’Machine ON’ LED goes out (1). Switch off and lock out the supply disconnecting device. Switching Off in an Emergency and Switching On Again Fig.
Operation Remote On and Off Switching Pre --- condition: A remote control device is connected. Apply the remote warning label to the machine where it is plainly visible. BEWARE! This machine is remotely controlled and can start at any time. Label the remote control device accordingly: ”Before starting, make sure that no one is working on the machine and it can be safely started.”...
Operation Alarm message An alarm shuts the machine down automatically. The red ’Alarm’ LED blinks (11). The display shows the latest acquired value Alarm coming LED flashes Alarm acknowledged LED illuminates Alarm reset LED out Alarm coming LED flashes Alarm reset LED flashes Alarm acknowledged LED out...
Event Recognition and Fault Rectification Event Recognition and Fault Rectification Inform KAESER service if the event cannot be rectified by the action suggested. Do not attempt rectifications other than those given in this manual. The measures valid for your machine are dependant on the individual equipment.
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Investigate cause of shut- because of overload. down. Reset overload trip. HT cell Fault in the high tension Contact KAESER service. cell. mains cont. on? The mains contactor does Check mains contactor and not pull in despite ON com- wiring.
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Check the machine for pressed air. leaks. Working pressure stays Check coupling / V---belts below 3.5 bar within a Contact KAESER service. preset period. oil p ¡ No changeover to load as Check oil circulation. long as the minimum oil Check pressure switch, line pressure is not reached.
Check transducer connec- the sensor and the analog tions and wiring. input is shorted. soft start Fault in the soft start equip- Contact KAESER service. ment. Airend discharge tempera- Heat the compressor room. Start ¡ ture (ADT) too low. Ambient temperature below + 3˚...
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0 Customer specific: Customer specific: No data No data ext. message 5 flash memory Internal controller memory Contact KAESER service. error. FC mains Failure of power supply to Check power supply. the frequency converter. mains voltage ¢ 1. power failure: Check power supply volt- Machine was re–started...
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Increase cross–section of piping between compressor and air receiver. The service interval for the Have an authorized motor bearings h motor bearing change has KAESER technician replace expired. the motor bearings. Neutral p–switch Customer specific: No data Neutral T–switch Customer specific: No data no press.buildup...
Event Recognition and Fault Rectification Message Possible cause Remedy PD temperature Warning Contact KAESER service. Compressor outlet (pack- age discharge) temperature is low. PD temperature Warning Clean the cooler. ¡ Compressor outlet (pack- Check the cooling oil level. age discharge) temperature too high.
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Event Recognition and Fault Rectification Fault Possible cause Remedy Machine runs but produces Inlet valve not opening or no compressed air. no compressed air. only opening partially. Venting valve not closing. Leaks in the pressure sys- Check pipework and con- tem.
Maintenance Maintenance 10.1 Safety Any disregard of these instructions and/or incorrect handling may result in serious injuries. Voltage! DANGER There is danger of fatal injury caused by touching electrically live compo- nents. Isolate all phases of the main power supply. (switch off the mains supply disconnecting device) Ensure that the power supply cannot be switched on again (locked off).
Keep a log of all service work. ¡ This enables the frequency of individual maintenance tasks to be compared with KAESER’s recommendations. A list is given in chapter 10.16. 10.2.1 Resetting maintenance interval counters Maintenance interval counters indicate the operating hours between maintenance tasks.
Machine duty cycle and ambient conditions are important criteria for the number and length of the change intervals. KAESER Service will support you in determining appropriate intervals and provide information on the possibilities of oil analysis. Check operating conditions and adjust intervals as necessary; keep results in a table 42for future reference.
Cooling oil changing intervals 10.2.4 Regular service work Only authorised KAESER service agents should carry out service work. When operating conditions are unfavourable (e. g. dusty atmosphere) or when the equipment is heavily utilised, service work must be carried out more frequently.
Contamination causes overheating and machine damage. Avoid dust disturbance. Wear breathing apparatus if necessary. Do not use sharp objects to clean the cooler. The cooler could be damaged. A severely contaminated cooler should be cleaned by a KAESER service agent. Fig. 20 Cleaning the cooler...
Pressure in the cooling oil circuit is generally higher than that in the cooling water system. If a leak occurs, oil will run into the cooling water. Check the cooler visually for leaks. Have an authorised KAESER service agent check the cooler for internal leaks at least once a year. 10 --- 57...
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is dependant on the characteristics of the heat transfer medium. Contamination Have an authorised KAESER service agent clean the heat exchanger as soon as a pressure drop in the heat transfer medium is detected. Leakage If a leak occurs, cooling oil can flow into the heat transfer medium as pressure the cooling oil circuit is generally higher.
Maintenance Open the air filter housing: Unscrew the nuts (4) and lift out the cover (3) together with the air filter cartridge (2). Unscrew the nut (1) and remove the air filter cartridge. Do not clean the air filter cartridge with liquids. All sealing surfaces are matched to each other.
Maintenance Fig. 23 Ventilator grill Ventilator grill Filter mat Removal Remove the ventilator grill (1) and the filter mat (2). Cleaning Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash the mat in lukewarm water (40 ˚ C) and household detergent then rinse thoroughly. Renew the mat if cleaning is not possible or has already been carried out five times.
Maintenance Compressor motor The motor bearings are fitted with grease nipples. Fig. 24 Compressor motor maintenance Grease nipple Clean the grease nipple (1) with a rag. Apply the quantity of grease as stated on the motor nameplate. Grease both bearings with a grease gun. Close all access doors;...
Remove the fixing screws from the safety screen (1). ¡ Turn the coupling my hand and look for damage or colour change. ¡ Have a damaged coupling changed by an authorised KAESER Service agent. ¡ Refit the safety screen. ¡...
Maintenance Carry out the test exactly as described in the SIGMA CONTROL manual. Blowoff protection and system pressure monitoring are switched off during the test. The machine may only be operated with a correctly functioning pressure relief valve. Close the user’s shut ---off valve between the machine and the air main. Read the blowoff pressure on the valve.
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If manual venting does not bring the oil separator tank pressure gauge ¡ to zero, call KAESER service. Manually venting the oil separator tank With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl- ¡...
Maintenance Manually venting the compressed air cooler With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl- ing (1). Open the shut ---off valve (7) slowly to release pressure. Withdraw the male hose fitting and close the shut ---off valve. 10.12 Checking and Topping up the Cooling Oil 10.12.1 Check cooling oil level.
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Make sure that the shut ---off valve is closed. If manual venting does not bring the oil separator tank pressure gauge to zero, call KAESER service. Manually venting the oil separator tank With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl- ing (3).
Maintenance Manually venting the compressed air cooler With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupl- ing (1). Open the shut ---off valve (7) slowly to release pressure. Withdraw the male hose fitting and close the shut ---off valve. Topping up the cooling oil Open the filler plug (4) slowly.
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Maintenance Fig. 30 Changing the cooling oil, oil separator tank Hose coupling (air cooler venting) Male hose coupling/fitting Pressure gauge Shut ---off valve A: closed B: open Hose coupling (oil separator tank vent- Maintenance hose ing) Oil filling port with plug Hose coupling (oil drain) Oil level indicator Shut ---off valve (venting line)
Close the shut ---off valve (7) and withdraw the hose fitting from the coupling. 10.13.1 Draining the oil from the separator tank Contact KAESER Service if condensate is detected in the oil. It is necessary to adjust the airend discharge temperature to suit operating conditions.
Maintenance Have an oil container ready. With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupling (2). Place the end of the maintenance hose in the oil container and secure it in place. Open the shut ---off valve (3). Open the shut ---off valve (7) slowly and allow oil and air to drain completely.
Maintenance Remove the protective screen (1, Fig. 33) and turn the coupling (2, Fig. 33) by hand at least five revolutions until all the oil has run out. Replace and secure the safety screen (1, Fig. 33). Close the shut ---off valve (3) and unplug the hose. Turning the coupling can cause a small amount of oil to flow back to the cooler and separ- ator tank.
Maintenance 10.13.6 Start the machine and carry out a test run. Open the shut ---off valve (10, Fig. 30) in the venting line. Close all access doors; replace and secure all removable panels. Open the user’s shut ---off valve between the machine and the air main. Switch on the power supply and reset the maintenance interval counter.
Maintenance Screw on the new filter using hand pressure only. Do not use any tool. The oil filter is turned clockwise to tighten. Start the machine and carry out a test run Close all access doors; replace and secure all removable panels. Open the user’s shut ---off valve between the machine and the air main.
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Maintenance Unscrew the fitting (20) and carefully put the parts to one side; pull out the copper pipe at item (15). Unscrew the fittings (19) from the ends of the air pipe (16). Withdraw the air pipe from the minimum pressure/check valve (25) and push carefully to one side.
Use only genuine spare parts and authorised operating materials. Have an authorised KAESER service agent carry out regular mainten- ance. KAESER maintenance parts and operating materials correspond to the original. These are correct for use in our machines. Machine Name...
Wrap the machine in plastic sheeting. ¡ Transport packaging A wooden crate is required for overland transport to protect the machine from mechanical damage. Consult an authorised KAESER service agent for advice on packaging for sea or air trans- port. 12 --- 83...
Store the machine in a dry, frost ---free room. Prevent ingress of moisture and condensation. Advice can be obtained from KAESER on suitable storage and initial start ---up. Moisture can lead to corrosion, particularly on the surfaces of the airend and oil separator tank.
De --- commissioning, Storage and Transport 12.4.3 Transverse beams Pre --- condition: The lifting cradle complies with local safety regulations. No pressure bears on the sides of the machine cabinet. Incorrect application of the lifting cradle can damage the machine. CAUTION Do not attach the lifting cradle to any of the machine components.
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Kindly assist with the part number of shaft seal for csd 105