KAESER ESD 442 SFC Technical Documentation Manual
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KAESER ESD 442 SFC Technical Documentation Manual

KAESER ESD 442 SFC Technical Documentation Manual

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Table Of Contents
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Table of Contents

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Compressor-Typ: ESD 442 SFC / 14 bar (a), ac, Helium
Compressor-No.: ESD.2C / Serial-No.: 1205

Table of Contents

1.
2.
3.
Service manual compressor
4.
Service manual Sigma Control
5.
6.
Performance test by helium #100714
7.
Measurement record for units with suction side gas
supply
8.
Quality-Dimensions-Material-Surface #100713
Project: Florence12 / L.00478
Order-No.: 10357405

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Summary of Contents for KAESER ESD 442 SFC

  • Page 1 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 Table of Contents Dimensional drawing Electrical diagram Service manual compressor Service manual Sigma Control Spare Parts List...
  • 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 Electrical connections Cooling air outlet as required 1 5/8 1 5/8 7 1/8 3 7/8 5 1/8 4 x dia.26 2 x dia.75 Electrical connections as required Gas inlet ANSI 4" / 150lbs 5 7/8 25 7/8 64 5/8 2 1/2 2 x dia.75 62 1/4 24 1/4...
  • 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...
  • 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 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...
  • 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 Contents Regarding this document Using this document ......................Further documents ......................Copyright .......................... Symbols and labels ......................1.4.1 Warnings ......................1.4.2 Potential damage warnings ................1.4.3 Other alerts and their symbols ................Technical Specifications Nameplate ........................Options ..........................Weight ..........................Temperature ........................
  • Page 40 Contents Function description ......................Frequency converter ......................Floating relay contacts ..................... Options ..........................4.5.1 Water cooling ...................... 4.5.2 Machine mountings ..................... 4.5.3 Cooling air filter mat .................... Operating modes ......................4.6.1 Operating modes ....................Variable speed with frequency converter (SFC) .............. Safety Devices .........................
  • Page 41 10.20 Documenting maintenance and service work ..............Spares, Operating Materials, Service 11.1 Note the nameplate ......................11.2 Ordering consumable parts and operating fluids/materials ..........11.3 KAESER AIR SERVICE ....................11.4 Service Addresses ......................Decommissioning, Storage and Transport 12.1 Putting Out of Operation ....................
  • Page 42 Contents Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 43 List of Illustrations Fig. 1 Mass flow rate and regulating range ..................Fig. 2 Correct use of RCD ........................Fig. 3 Location of safety signs ......................Fig. 4 Enclosure overview ........................Fig. 5 Machine layout ........................... Fig. 6 Machine mountings ........................Fig.
  • Page 44 List of Illustrations Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 45 List of Tables Tab. 1 Danger levels and their definition (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 Nameplate ..........................Tab. 4 Options ............................Tab. 5 Machine weight .......................... Tab. 6 Temperature ..........................Tab.
  • Page 46 List of Tables Service Manual Screw Compressor viii ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 47 Copyright This service manual is copyright protected. Queries regarding use or duplication of the documenta‐ tion should be referred to KAESER. Correct use of information will be fully supported. Symbols and labels ➤ Please note the symbols and labels used in this document.
  • Page 48 Regarding this document Symbols and labels DANGER The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐ jury will occur.
  • Page 49 Regarding this document Symbols and labels Material Here you will find details on special tools, operating materials or spare parts. Precondition Here you will find conditional requirements necessary to carry out the task. The conditions relevant to safety shown here will help you to avoid dangerous situations. Option H1 ➤...
  • Page 50 Technical Specifications Nameplate 2 Technical Specifications Nameplate The model designation and important technical information are given on the machine's nameplate. The nameplate is located on the outside of the machine: ■ above the cooler, or ■ on the rear of the machine. ➤...
  • Page 51 Technical Specifications Temperature ESD 442 Weight [kg] 5825 Tab. 5 Machine weight Temperature ESD 442 Minimum cut-in tempera‐ ture [°C] Typical airend discharge 65–100 temperature during oper‐ ation [°C] Maximum airend dis‐ charge temperature (au‐ tomatic safety shut-down) [°C] Tab. 6 Temperature Ambient conditions ESD 442...
  • Page 52 Technical Specifications Pressure ESD 442 Extractor for forced venti‐ 75000 lation: Flow rate [m /h] at 100 Pa Tab. 8 Ventilation Pressure ESD 442 Intake pressure [bar] 1.05 (abs) ± 0.05 (abs) Operating pressure [bar] 14.0 (abs) ± 0.1 (abs) Relationship: >5 Operating pressure/...
  • Page 53 Technical Specifications Cooling oil Fig. 1 Mass flow rate and regulating range mass flow rate 20 mA ≙ 50 Hz maximum mass flow rate at signal 4 mA ≙ 20 Hz minimum mass flow rate at signal Amperage Signal [mA] Frequency [Hz] Mass flow rate [g/s] 31.1...
  • Page 54 Technical Specifications 2.10 Cooling oil charge HCF 12 Viscosity at 40 °C 43.3 cst Viscosity at 7.45 cst 100 ℃ Flash point 268℃ Density at 20 ℃ 839 kg/m Pour point -57 ℃ Tab. 12 Cooling oil recommendation 2.10 Cooling oil charge ESD 442 Total charge [litres] Topping up volume [l]...
  • Page 55 Technical Specifications 2.12 Noise emission [dB(A)] ESD 442 Oil cooler Air cooler Protection rating IP 55 IP 55 Motor bearing re-greas‐ 4000 4000 ing interval [h] Grease requirement, each bearing [g]* h = operating hours * Copy the data from the motor nameplate into the table. Tab.
  • Page 56 Technical Specifications 2.14 Power supply specifications Further requirements RCD Type A: A Type A RCD cannot detect residual DC currents in the event of a UPS system, Frequency Con‐ verter, or other types of device in which DC is utilized faults. Because of the presence of these DC residual currents, a Type A device is ineffective at sensing AC residual currents or pulsating DC currents therefore the device may not trip if a fault occurs.
  • Page 57 It is imperative that measures for cooling water treatment and filtration are implemented and performed. KAESER can provide the names of companies specialising in cooling water analysis and the supply of suitable treatment devices. The following design types are available: ■...
  • Page 58 Maximum working pres‐ sure [bar] Max. permissible dis‐ charge temp. [°C] Maximum flow rate [m Unsuitable cooling medi‐ Sea water Consult KAESER on the suitability of water. Tab. 20 Specification: Heat exchanger (Option K2) 2.15.1.2 Cooling water quality Characteristics/content Closed cooling sys‐...
  • Page 59 Technical Specifications 2.15 Water cooling Characteristics/content Closed cooling sys‐ Open cooling system Chlorides (Cl) [mg/l] <100 <100 Iron (Fe), dissolved [mg/l] <0,5 <0,2 Sulphate (SO ) [mg/l] <300 <300 ratio >1 >1 Electrical conductivity [µS/cm] 10–800 10–1500 <1 <1 Ammonia (NH ) [mg/l] Manganese (Mn), dissolved [mg/l] <0,1...
  • Page 60 Technical Specifications 2.15 Water cooling ESD 442 Unsuitable cooling medi‐ Salt water Consult KAESER on the suitability of water. Tab. 23 Specification: Heat exchanger (Option K9) 2.15.2.2 Cooling water quality Characteristics/content Closed cooling sys‐ Open cooling system pH value 6,0 – 9,0 6,5 –...
  • Page 61 Safety and Responsibility Basic instructions 3 Safety and Responsibility Basic instructions The machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■...
  • Page 62 Safety and Responsibility User's responsibilities 3.4.2 Defining personnel Suitable personnel are experts who, by virtue of their training, knowledge and experience as well as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐ sible dangers involved.
  • Page 63 Safety and Responsibility Dangers Inspection Inspection interval Inspecting authority Strength test Every 10 years after installation or the last Approved supervisory body inspection Tab. 25 Inspection intervals according to Ordinance on Industrial Safety and Health Dangers Basic instructions The following describes the various forms of danger that can occur during machine operation. Basic safety instructions are found in this service manual at the beginning of each chapter in the section entitled 'Safety'.
  • Page 64 Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine. ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER replacement parts on pressure bearing parts. Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 65 Safety and Responsibility Dangers Conversion or modification of the machine Modifications, additions to and conversions of the machine or the controller can result in unpredict‐ able dangers. ➤ Do not convert or modify the machine! ➤ Obtain written approval by the manufacturer prior to any technical modification or expansion of the machine, the controller, or the control programs.
  • Page 66 ➤ Allow the machine to cool down. ➤ Do not open the cabinet while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 67 Safety and Responsibility Safety devices ➤ Carry out regular inspections: for visible damages, of safety installations, of the EMERGENCY STOP command device, of any components requiring monitoring. ➤ Pay particular attention to cleanliness during all maintenance and repair work. Cover compo‐ nents and openings with clean cloths, paper or tape to keep them clean.
  • Page 68 Safety and Responsibility Safety Signs ➤ Regularly check safety devices for their correct function. ➤ Do not remove or obliterate labels and notices. ➤ Ensure that labels and notices are clearly legible. Further information More information on safety devices is contained in chapter 4, section 4.8. Safety Signs The diagram shows the positions of safety signs on the machine.
  • Page 69 Serious injury or death can result from loosening or opening component that is un‐ der pressure and heavily spring loaded! ➤ Do not open or dismantle the valve. ➤ Call for authorized KAESER Service representative if a fault occurs. Serious injury or death can result from loosening or opening component under pres‐ sure! ➤...
  • Page 70 Safety and Responsibility Warranty ➤ Shut off supply lines if possible. Mains disconnecting device (all poles) Cooling water (if present) Heat recovery (if present) ➤ Warn and move endangered personnel to safety. ➤ Help incapacitated persons. ➤ Close the door(s). ➤...
  • Page 71 ■ incorrect maintenance, ■ incorrect repair. Correct maintenance and repair includes 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 machine may cause dangers for the environment.
  • Page 72 Design and Function Enclosure 4 Design and Function Enclosure Fig. 4 Enclosure overview Control cabinet door Access door Latch Panel (removable) When closed, the enclosure serves various functions: ■ Sound insulation ■ Protection against contact with components ■ Cooling air flow The enclosure is not suitable for the following uses: ■...
  • Page 73 Design and Function Frequency converter Fig. 5 Machine layout Inlet valve Airend Minimum pressure/check valve Control cabinet Compressor drive motor Oil separator tank Oil filter Oil/gas cooler Gas delivered to the machine by pipeline is drawn into the airend and compressed. The airend is driven by an electric motor Cooling oil is injected into the airend.
  • Page 74 Design and Function Options Options The options available for your machine are described below. 4.5.1 Option K2/K9 Water cooling Stainless steel plate-type heat exchanger (Option K2) or bundled pipe heat exchangers (Option K9) are used in machines with water cooling. 4.5.2 Option H1 Machine mountings...
  • Page 75 Design and Function Operating modes Operating modes 4.6.1 Operating modes The machine operates in the following modes: ■ LOAD: The inlet valve is open. The airend delivers gas into the gas network. The compressor motor runs under full load. ■ STANDSTILL: The inlet valve is closed.
  • Page 76 Design and Function Operating panel SIGMA CONTROL 2 Operating panel SIGMA CONTROL 2 Keys Fig. 8 Keys - overview Item Description Function «OFF» Switch the machine off. «ON» Switch on the machine. «Escape» Returns to the next higher menu option level. Exits the edit mode without saving.
  • Page 77 Design and Function Operating panel SIGMA CONTROL 2 Indicators Fig. 9 Indicators - overview Item Description Function Indicator field or dis‐ Graphic display with 8 lines and 30 characters. play Alarm Flashes red when an alarm occurs. Lights continuously when acknowledged. Communication Continuous red illumination if a communication connection (Ethernet, USS, COM modules) has a fault.
  • Page 78 Design and Function Operating panel SIGMA CONTROL 2 RFID sensor field RFID is the abbreviation for “Radio Frequency Indentification” and enables the identification of per‐ sons or objects. Placing a suitable transponder in front of the RFID sensor field of the controller will automatically activate the communication between transponder and SIGMA CONTROL 2 .
  • Page 79 The distances quoted are recommended distances and ensure unhindered access to all ma‐ chine parts. ➤ Please consult KAESER if you cannot comply with these recommendations. Precondition The floor must be level, firm and capable of bearing the weight of the machine.
  • Page 80 It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐ tions. ➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of the machine room. 1. Ensure that the volume of air flowing into the machine room is at least equivalent to that being removed from it by the machine and exhaust fan.
  • Page 81 The machine can only overcome the air resistance at the cooling air inlet and exhaust determined by the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐ ing. ➤ Consult the KAESER service representative before deciding on: ■ the design of the exhaust air ducting ■...
  • Page 82 Installation and Operating Conditions Operating the machine in a compressed gas network ➤ The machine is delivered without a gas inlet filter. The inlet gas must be: ■ clean ■ ■ pure ■ chemically inert ■ free of solid particles larger than 3 — 4 µm ■...
  • Page 83 Installation Ensuring safety 6 Installation Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
  • Page 84 Installation Reporting Transport Damage When working on the drive system Touching voltage carrying components can result in electric shocks, burns or death. Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result in serious injury.
  • Page 85 Installation Connecting the power supply 1. WARNING! Serious injury or death can result from loosening or opening components under pressure. ➤ The machine is charged with 0.5 bar gauge pressure. ➤ De-pressurise all pressurised components and enclosures. 2. A shut-off valve must be installed by the user in the connection line. 3.
  • Page 86 This ensures optimum compressor regulation with regard to the network pressure at the selected location. Safety monitoring of the machine's internal pressure is unaffected. Your authorized KAESER Service Technician will be glad to provide support on planning and executing an individual solution. 1. Install the isolating transformer in the control cabinet.
  • Page 87 Individual machines may not receive an adequate flow under this system. Break‐ downs are the result. ➤ KAESER can advise on how to ensure the cooling water supply via suitable control valves. Fig. 13...
  • Page 88 Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Please take note of all safety instructions Disregard of safety notes can cause unforeseeable dangers! ➤...
  • Page 89 ➤ Change the oil filter. ➤ Change the oil separator cartridge. ➤ Change the cooling oil. ➤ Have the motor bearings checked by an authorised KAESER Service Techni‐ cian. ➤ Have the frequency converter smoothing capacitors formed by an authorised KAESER Service Technician.
  • Page 90 Initial Start-up Commissioning the Frequency Converter To be checked Complied? chapter ➤ Are the power supply cable conductor cross-sections and fuse ratings 2.14 adequate? ➤ Fan motor overload protection switch set according to the mains volt‐ age? ➤ Have all electrical connections been checked for tightness? –...
  • Page 91 Initial Start-up Filling cooling oil into the airend Material 4 l Cooling oil from separator tank Precondition The supply disconnecting 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 bar.
  • Page 92 ➤ Check the motor overload protection switch setting. The overload protection switch shuts the machine down despite being correctly set? ➤ Contact KAESER Service. Evacuating the machine Before initial start-up the compressor must be evacuated and then filled with gas.
  • Page 93 Initial Start-up 7.10 Checking the direction of rotation ➤ Watch for any faults occurring in the first hours of operation. ➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐ essary. 7.10 Checking the direction of rotation The machine is designed for a clockwise phase sequence.
  • Page 94 Operation Switching on and off 8 Operation Switching on and off Always switch the machine on with the «ON» key and off with the «OFF» key. A power supply disconnecting device has been installed by the user. Fig. 16 Switching On and Off Machine ON LED (green) «LOAD/IDLE»...
  • Page 95 Operation Switching off in an emergency and switching on again Result Control voltage LED extinguishes. The machine is switched off and disconnected from the mains supply. Switching off in an emergency and switching on again The EMERGENCY STOP push-button is located below the control panel. Fig.
  • Page 96 Operation Switching on and off with the clock Fig. 18 Switching on and off from a remote control centre «Remote control» key Remote control LED 1. Attach an easily seen notice to the machine that warns of remote operation. Remote control: danger of unexpected starting! ➤...
  • Page 97 Operation Interpreting operation messages Fig. 19 Switching on and off with the clock «Clock» key Clock LED 1. Attach an easily seen notice warning of time-controlled operation: Clock control: danger of unexpected starting! ➤ Make sure the power supply disconnecting device is switched off before commencing any work on the machine.
  • Page 98 Operation Acknowledging alarm and warning messages Fig. 20 Acknowledging messages Warning (yellow) Alarm (red) Key«Acknowledge» Alarm message alarm LED flashes. An alarm shuts the machine down automatically. The red The system displays the appropriate message. Precondition The fault has been rectified ➤...
  • Page 99 1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorized KAESER service representative. Further information Detailed information for the various messages can be found in the service manual SIGMA CONTROL 2 .
  • Page 100 Fault Recognition and Rectification Other faults Alarm Possible cause Remedy Cooling oil leaking into the floor Hose coupling or maintenance Remove coupling or mainte‐ pan. hose still plugged into the nance hose. quick-release coupling on the oil separator tank. Oil cooler leaking. Contact KAESERservice.
  • Page 101 Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
  • Page 102 ➤ Linde regulations have priority and should be observed in all maintenance and service work. 10.3 Following the maintenance plan 10.3.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work at shorter intervals. Adverse conditions are, e.g.: ■...
  • Page 103 Maintenance 10.3 Following the maintenance plan 10.3.2 Resetting maintenance interval counters According to the way a machine is equipped, sensors and/or maintenance interval counters moni‐ tor the operational state of important functional devices. Required maintenance work is shown on SIGMA CONTROL 2 . Precondition Maintenance performed and maintenance message acknowledged.
  • Page 104 Check the oil collecting tank 10.3.4 Regular service tasks The table below lists necessary service tasks. ➤ Only an authorised KAESER service technician should carry out service work. ➤ Have service tasks carried out punctually taking ambient and operating conditions into ac‐ count. Interval...
  • Page 105 Clogged coolers are indicative of unfavourable ambient conditions. Such ambient conditions clog the cooling air ducts in the machine's interior and the motors resulting in increased wear and tear. ➤ Have the authorised KAESER Service clean the cooling air ducts. Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 106 ➤ Dry brush the oil and gas coolers and use a vacuum cleaner to suck up the dirt. The gas and oil coolers can no longer be properly cleaned? ➤ Have stubborn clogging removed by an authorized KAESER Service Technician. Check the cooler for leaks ➤...
  • Page 107 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. 1. Check the cooler visually for leaks. 2. Have an authorised KAESER Service Technician check the cooler for internal leaks at least once a year. Cleaning ➤...
  • Page 108 Maintenance 10.9 Motor maintenance Removal 1. Open the fixing by turning 90° anti-clockwise with a screwdriver. 2. Remove the frame Cleaning ➤ Renew the mat if cleaning is not possible or has already been carried out five times. ➤ Beat the mat or use a vacuum cleaner to remove loose dirt.
  • Page 109 2. Grease both bearings with a grease gun. 3. Reset the maintenance interval counter. Option K2/K9 Fan motor: ➤ Have the fan motor bearings checked by a KAESER Service Technician during the regular maintenance calls. 10.10 Checking the Coupling A defective coupling is recognisable by: ■...
  • Page 110 3. Refit the safety screen. 4. Close all access doors and replace all enclosure panels. 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 valve, the machine's working pressure is raised above the acti‐...
  • Page 111 ➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐ ual. The machine does not shut down? ➤ Have the safety shutdown function checked by an authorised KAESER Service Techni‐ cian. 10.13 Checking the cooling oil level In frequency-controlled compressors (SFC) the oil level indicator is only accurate when the machine is running at or near maximum speed.
  • Page 112 Maintenance 10.14 Venting the machine (de-pressurising) Fig. 27 Checking the cooling oil level Minimum oil level Maximum oil level Optimum oil level 1. CAUTION! Danger of burning - hot surfaces! ➤ Wear long-sleeved clothing and protective gloves. 2. Check the oil level with machine running under LOAD. Result As soon as the minimum level is reached: Replenish the cooling oil.
  • Page 113 ➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact KAESER Service. Vent gas manually from the gas cooler After shutting down the compressor and venting the oil separator tank, the machine is still un‐...
  • Page 114 Maintenance 10.15 Replenishing the cooling oil 10.15 Replenishing the cooling oil The machine must be isolated from the compressed gas network and completely vented be‐ fore undertaking any work on the pressure system. Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath the oil separator tank.
  • Page 115 ➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact the KAESER Service. Vent gas manually from the gas cooler. After shutting down the compressor and venting the oil separator tank, the machine is still un‐...
  • Page 116 Compressor block ➤ Always change the oil filter and oil separator cartridge when changing the oil. ➤ Contact KAESER Service if condensate is detected in the cooling oil. It is necessary to adjust the airend discharge temperature to suit operating conditions.
  • Page 117 Maintenance 10.16 Changing the cooling oil Fig. 30 Changing the cooling oil, oil separator tank Hose coupling (air cooler venting) Shut-off valve open Pressure gauge Shut-off valve closed Hose coupling (oil separator tank venting) Maintenance hose Oil filler port with plug Hose coupling (oil drain) Cooling oil level indicator Shut-off valve (venting line)
  • Page 118 Maintenance 10.16 Changing the cooling oil 3. Place the other end of the maintenance hose in the oil receptacle and secure it in place. 4. Open the shut-off valve 5. Slowly open the shut off valve in the maintenance hose to release oil and close immediately when air escapes.
  • Page 119 Maintenance 10.16 Changing the cooling oil Draining the oil from the airend Fig. 32 Changing the cooling oil, airend Airend gas discharge point Safety screen Hose coupling (oil drainage) Coupling Shut-off valve 1. Have an oil receptacle ready. 2. With the shut-off valve closed, insert the male hose fitting (Fig.
  • Page 120 Maintenance 10.17 Changing the oil filter 3. Switch on the power supply and reset the maintenance interval counter. 4. Start the machine and check the oil level again after about 10 minutes, topping up if necessary. 5. Switch off the machine and check visually for leaks. ➤...
  • Page 121 Maintenance 10.18 Changing the oil separator cartridge 2. Unscrew the oil filter anti-clockwise, catch oil spillage and dispose of in accordance with envi‐ ronmental protection regulations. 3. Lightly oil the new filter's O-ring. 4. Turn the oil filter clockwise by hand to tighten. ➤...
  • Page 122 Maintenance 10.18 Changing the oil separator cartridge Opening the machine enclosure Fig. 34 Open the enclosure (oil separator cartridge changing) Access panel Cover plate 1. Remove enclosure panels 2. Remove the cover plate Changing the oil separator cartridge ➤ Lift the oil separator cartridge with lifting tackle or the aid of at least one other person. Fig.
  • Page 123 Maintenance 10.18 Changing the oil separator cartridge 2. Unscrew the fitting and carefully put the parts to one side, then pull out the copper pipe from the dirt trap 3. Loosen the fitting and disconnect the air pipe completely if necessary. 4.
  • Page 124 Maintenance 10.19 Assembling flexible pipe connections 10.19 Assembling flexible pipe connections With the machine depressurized, the clamping bolts must be freely movable by hand and par‐ allel with the pipe. All clamping bolts must be equally loaded. ➤ Replace the self-locking nuts. Fig.
  • Page 125 Maintenance 10.20 Documenting maintenance and service work 10.20 Documenting maintenance and service work Machine number: ➤ Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 41 Logged maintenance tasks Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 126 ➤ Please give the information from the nameplate with every enquiry and order for spares. 11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original Kaeser products. They are selec‐ ted for use in KAESER machines. Unsuitable or poor quality consumable parts and operating fluids/materials may damage the ma‐...
  • Page 127 Spares, Operating Materials, Service 11.4 Service Addresses ➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement. Your advantage: lower costs and higher compressed gas availability. 11.4 Service Addresses Addresses of KAESER agents are given at the end of this manual.
  • Page 128 Packing A wooden crate is required for overland transport to protect the machine from mechanical damage. Other measures must be taken for the transport of machines by sea or air. Please contact KAESER SERVICE for more information. Material Desiccant Plastic sheeting...
  • Page 129 Weight and centre of gravity determine the most suitable method of transportation. The centre of gravity is shown in the drawing in chapter 13.2. ➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐ tures.
  • Page 130 Attached components such as cyclone separators, condensate drains or filters ■ Rain protection covers ➤ Please consult with KAESER if you have questions to the appropriate lifting gear. Precondition The lifting gear complies with local safety regulations. No pressure should bear on the sides of the machine cabinet.
  • Page 131 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 134 Annex 13.2 Dimensional drawing 13.2 Dimensional drawing Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 135 Annex 13.2 Dimensional drawing Electrical connections Cooling air outlet as required 1 5/8 1 5/8 7 1/8 3 7/8 5 1/8 4 x dia.26 2 x dia.75 Electrical connections as required Gas inlet ANSI 4" / 150lbs 5 7/8 25 7/8 64 5/8 2 1/2 2 x dia.75...
  • Page 136 Annex 13.3 Electrical Diagram 13.3 Electrical Diagram Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 142 Annex 13.3 Electrical Diagram Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 143 Annex 13.3 Electrical Diagram Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 144 Annex 13.3 Electrical Diagram Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 145 Annex 13.3 Electrical Diagram Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 146 Annex 13.3 Electrical Diagram Service Manual Screw Compressor ESD 442/14 bar (abs) SFC SIGMA CONTROL 2 ESD_2C_10357405_10–LIN_00 E...
  • Page 168 Annex 13.3 Electrical Diagram 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 Quick 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 174 Contents Important settings ......................Setting the contrast and the brightness ................Setting the display language .................... Logging on with Equipment Card ..................Adjusting the system setpoint pressure ................Activating the «clock» key....................Activating the «<Remote control»> key ................Changing the control mode ....................Outputting important operational states of the machine ...........
  • Page 175 Contents Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03 USE...
  • Page 176 Important settings 1 Important settings In this chapter, important or often used settings are explained in brief. Detailed information on func‐ tion, configuration, fault removal and important instructions concerning safe operation are found in subsequent chapters. Setting and other work on the machine may only be carried out by the following persons: ■...
  • Page 177 Setting the contrast and the brightness 2 Setting the contrast and the brightness The display settings for contrast and brightness are set to the highest possible values by default. Change the settings if adverse lighting conditions make it difficult to read the displayed information. Optimizing the contrast settings: ■...
  • Page 178 Setting the display language 3 Setting the display language Precondition The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Press the «UP» or «DOWN» keys until the current language is shown as active line. 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 179 4. Note the number shown on the backside of the Equipment Card. 5. Store this information at a suitable location. Log on with Equipment Card Use a supplied KAESER Equipment Card to log on at the controller. Two of them have been provided with the machine. Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.1.3...
  • Page 180 Logging on with Equipment Card Fig. 2 RFID reader 1. Hold the Equipment Card for a short time in front of the RFID reader. The data are read. Your user name and access level are displayed. 2. Press «Enter» to confirm the log-on. The operating mode is displayed.
  • Page 181 Adjusting the system setpoint pressure 5 Adjusting the system setpoint pressure Precondition Access level 2 is activated. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. < Configuration ➙ Pressure control ➙ Pressure settings > menu. 2.
  • Page 182 Activating the «clock» key. 6 Activating the «clock» key. Activating/deactivating the check box Check box Check box for reset Status ☑ ☒ activated ☐ ☐ deactivated Tab. 1 Check box status Precondition Password level 2 is activated. The display shows the operating mode. Select the clock compressor menu 1.
  • Page 183 Activating the «clock» key. 9. Press «Enter» to accept the settings. The display stops flashing and the time (hours/minutes) is set. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Current menu 6 Compressor clock Key clock: ☐...
  • Page 184 Activating the «clock» key. Result The machine runs according to the defined switching points of the clock program. 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. Quick user guide Controller 9_9450 03 USE...
  • Page 185 Activating the «<Remote control»> key 7 Activating the «<Remote control»> key Further settings have to be made to allow the machine to be remotely controlled. ➤ Refer to the section "Additional information" in this chapter. Activating/deactivating the check box Check box Status ☑...
  • Page 186 Activating the «<Remote control»> key 6. Press «Enter» to save the setting. The «Remote control» key is activated and can be used. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.4.1 Compressor on Local mode: Key Remote mode: Key ------------------------------...
  • Page 187 Activating the «<Remote control»> key 6. Press «Enter» to accept the setting. The «Remote control» key is activated and can be used. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.3 Load control Local mode pA ·········...
  • Page 188 Changing the control mode 8 Changing the control mode The standard setting of the control mode depends on the machine type. As an example, the change from DUAL to QUADRO control mode is described below. Precondition Access level 2 is activated. The display shows the operating mode.
  • Page 189 Outputting important operational states of the machine 9 Outputting important operational states of the ma‐ chine Important operational machine states can be assigned via floating relay contacts as a binary signal on the outputs DOR 1.05 – DOR 1.07. Further outputs are optionally available. You can assign ev‐ ery output only once.
  • Page 190 Resetting maintenance interval counters 10 Resetting maintenance interval counters Example: Resetting the maintenance counter for the oil filter. Precondition Maintenance has been performed. Warning message has been acknowledged. Access level 2 is activated. The display shows the operating mode. Maintenance menu 1.
  • Page 191 Resetting maintenance interval counters 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 4 Maintenance Oil filter Active line, check box is deactivated 6000 h ¦ 6000 h Reset: ☐ ········· Oil separator 6000 h ¦...
  • Page 192 Safety relief valve checking 11 Safety relief valve checking Overview ■ Preparing the test ■ Performing the test ■ Correct 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.
  • Page 193 Safety relief valve checking 3. Press «Enter» to accept the setting. The test mode is now activated. The monitoring of internal and network set point pressures is deactivated! 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 9.1 TÜV inspection Active line with check box...
  • Page 194 Safety relief valve checking Resetting If the test is canceled when opening the safety relief valve, SIGMA CONTROL 2 will indicate the highest measured value as internal pressure. Activate the check box for reset in order to reset the stored value. ➤...
  • Page 195 Checking the temperature sensor and overheating shutdown function 12 Checking the temperature sensor and overheating shutdown function The machine should shut down if the airend discharge temperature (ADT) reaches a maximum of 230°F. SIGMA CONTROL 2 will simulate a higher temperature for checking this function. For this purpose, SIGMA CONTROL 2 automatically determines an offset value to be displayed.
  • Page 196 The machine will switch off as soon as the airend discharge temperature attains a value of 226°F . The machine does not shut down? ➤ Abort the test and contact KAESER Service as soon as possible. Correct conclusion of the test 1. Press «Enter» to switch into setting mode.
  • Page 197 Interpreting operation messages 13 Interpreting operation messages The controller will automatically display operation messages informing you about the current opera‐ tional state of the machine. Operating messages are identified with the letter O. The message numbers are not numbered consecutively. Messages 0081 to 0095 are customer-specific and undefined.
  • Page 198 Interpreting operation messages Message Meaning 0081 O 0082 O 0083 O 0084 O 0085 O 0086 O 0087 O 0088 O 0089 O 0090 O 0091 O 0092 O 0093 O p-Switch pi 0094 O T-Switch ADT 0095 O p-Switch pN 0200 O The internal voltage monitoring reports low voltage fault IOSlot1 IOSlot1 Undervoltage error 50...
  • Page 199 Interpreting operation messages Message Meaning 0205 O The internal voltage monitoring reports low voltage fault IOSlot6 IOSlot6 Undervoltage error 50 Tab. 4 Operational messages Quick user guide Controller SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03 USE...
  • Page 200 14 Interpreting diagnostic messages Diagnostic messages are identified with 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. Quick user guide Controller 9_9450 03 USE...
  • Page 201 Interpreting fault messages 15 Interpreting fault messages Alarm messages are identified with the letter A. The message numbers are not numbered consecutively. Messages 0081 to 0095 are customer-specific and may differ from the suggested values. Com‐ plete them with your defined message text, possible causes, and remedies. Message Possible cause Remedy...
  • Page 202 – – Internal pressure pi ⇟ 0021 A Refrigeration dryer: Contact an author‐ Refrigeration dryer T ⇟ Compressed air temperature ized KAESER too low. service representa‐ tive. 0022 A Oil separator cartridge clog‐ Change the oil Oil separator Δp ⇞...
  • Page 203 50 psi within a V-belts default period. 0045 A Thermostatic valve defective Contact an author‐ Compressor T ↓↓ ized KAESER service representa‐ tive. 0048 A Fault in the high voltage cell. Contact an author‐ High-voltage cell ized KAESER service representa‐...
  • Page 204 Drive belts or coupling bro‐ Drive belt: Back pressure run ken. Replace drive belts. Coupling: Contact an author‐ ized KAESER service representa‐ tive. 0061 A The rate of rise of the airend Check the cooling Oil separator rise dT/dt ⇞ discharge temperature is too oil level.
  • Page 205 Reset the overload relay. 0200 A Frequency converter fault Contact an author‐ Compressor motor USS alarm ized KAESER service representa‐ tive. 0201 A Frequency converter fault Contact an author‐ Compressor motor USS alarm ized KAESER service representa‐...
  • Page 206 Interpreting fault messages Message Possible cause Remedy 0211 A Frequency converter fault Contact an author‐ Compressor motor FC Motor overload alarm ized KAESER service representa‐ tive. Tab. 5 Fault messages and remedies Quick user guide Controller 9_9450 03 USE SIGMA CONTROL 2 SCREW FLUID 1.1.3...
  • Page 207 Oil separator cartridge clogged. 0007 W Drive motor bearing de‐ Contact KAESER Service. Motor bearings fective. 0008 W Maximum airend dis‐ Clean the cooler. Airend discharge temperature ADT ↑ charge temperature will Check the cooling oil level.
  • Page 208 Air filter: Change the air filter. Air filter h ⇞ Maintenance interval has elapsed. 0029 W Valves: Contact KAESER Service. Valve inspection h ⇞ Maintenance interval has elapsed. 0030 W Belt tension/coupling: Carry out a visual inspection. Belt/coupling inspection h ⇞...
  • Page 209 Keep ambient conditions Start temperature ↓ is too low (< 36°F). within specified limits. 0061 W The airend discharge Contact KAESER Service. Compressor T ↓ temperature (ADT) did not reach the minimum value within the speci‐ fied time. 0066 W...
  • Page 210 Interpreting warning messages Message Possible cause Remedy 0069 W Refrigerated dryer de‐ Immediately contact KAESER Error operation without RD → Call fective. service. service! Compressed air supply with undried air is acti‐ vated. 0070 W Refrigerated dryer: Maintain operating conditions.
  • Page 211 System messages are identified with the letter Y. The message numbers are not numbered consecutively. Message Possible Remedy cause 0001 Y System error Contact an authorized KAESER service Hardware watchdog reset representative. 0002 Y System error Contact an authorized KAESER service Internal software error representative.
  • Page 212 Selecting menu options ..................7.2.2 Changing the display language ................7.2.3 Noting the number of the KAESER Equipment Card ......... 7.2.4 Controlling access to the SIGMA CONTROL 2 with the Equipment Card ..7.2.5 Generating a password for the SIGMA CONTROL 2 ........
  • Page 213 Checking/setting the time and date ..............7.2.9 Setting display formats ..................7.2.10 Setting and activating summer/winter time ............Using KAESER CONNECT ..................... 7.3.1 Calling up KAESER CONNECT for SIGMA CONTROL 2 ......... 7.3.2 Displaying the system status ................7.3.3 Display graphs ....................7.3.4 Displaying messages ..................
  • Page 214 10.1 Maintenance Work ......................167 Spares, Operating Materials, Service 11.1 Note the nameplate ......................168 11.2 KAESER AIR SERVICE ....................168 11.3 Service Addresses ......................168 11.4 Displaying the version number, machine model, part number and serial number ... 168 Decommissioning, Storage and Transport 12.1 De-commissioning ......................
  • Page 215 Contents Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03USE...
  • Page 216 Keys – overview ......................... Fig. 3 Indicators – overview ........................Fig. 4 RFID sensor field ........................Fig. 5 KAESER CONNECT for SIGMA CONTROL 2 ................Fig. 6 Header ............................Fig. 7 Back of the KAESER Equipment Card ..................Fig. 8 Login window ..........................
  • Page 217 List of Illustrations Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03USE...
  • Page 218 List of Tables Tab. 1 Danger levels and their definitions (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 User interface ..........................Tab. 4 Display data ..........................Tab. 5 Interfaces ............................ Tab. 6 RFID ............................
  • Page 219 List of Tables Tab. 55 Profibus DP pin connection ......................Tab. 56 Master-slave configuration procedure ..................Tab. 57 Function diagram ........................115 Tab. 58 Example switching points ......................117 Tab. 59 Example for a clock program for equal duty cycling during the day ........... 120 Tab.
  • Page 220 ➤ Ensure that all amendments received are inserted into the operating manual. Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully support‐ 1.2.1 Software The software used in SIGMA CONTROL 2 contains copyright-protected software which is licensed by GNU General Public License in versions 2 and 3.
  • Page 221 Regarding this Document Symbols and labels Symbols and labels ➤ Please note the symbols and labels used in this document. 1.4.1 Warnings Warning notices indicate dangers that may result in injury when disregarded. Warning notices indicate three levels of danger identified by the corresponding signal word: Signal term Meaning Consequences of non-compliance DANGER...
  • Page 222 Regarding this Document Symbols and labels The type and source of the imminent danger is shown here! Potential effects when ignoring the warning are indicated here. ➤ The protective measures against the damages are shown here. ➤ Carefully read and fully comply with warnings against damages. 1.4.3 Other alerts and their symbols This symbol identifies particularly important information.
  • Page 223 Technical Data SIGMA CONTROL 2 Controller 2 Technical Data SIGMA CONTROL 2 Controller Industrial computer ■ Internal temperature monitoring ■ Internal undervoltage monitoring ■ Battery-buffered real-time clock ─ Battery life span more than 10 years ─ Battery replaceable 2.1.1 User interface with display, CPU and interfaces User interface Feature Value...
  • Page 224 The positions of the interfaces X1–X5 are marked on the rear of the controller. Tab. 12 Interfaces Identification with RFID Equipment Card Feature Value Hardware on the SIGMA CONTROL 2 controller RFID write/read device Hardware (external) KAESER Equipment Card Recognition distance [in] Max. 2 Frequency [MHz] 13.56 Tab. 13 RFID 2.1.2 Input/output modules There are three different types of input/output modules with different amounts of inputs and out‐...
  • Page 225 Technical Data SIGMA CONTROL 2 Controller Input/Output Input/output module 1 Internal, into available in External, into the control parallel on the compres‐ cabinet both sides sor interior Analog output current (AOI), 0–20 mA – – – Tab. 14 SC2IOM-1 IOM 2 Input/Output Input/output module 2 Internal, into...
  • Page 226 Technical Data SIGMA CONTROL 2 Controller Feature Value Current consumption IOM 3 [A] IOM ≙ input/output module Tab. 17 Power supply specifications 2.1.2.2 Maximum cable lengths Input/Output Conductor length [ft] Analog input current (AII), ＜ 100 Analog input resistor (AIR) Analog output current (AOI) Digital input (DI), ＜...
  • Page 227 Technical Data SIGMA CONTROL 2 Controller Feature Value Connection Twin cable Tab. 22 Resistance thermometer Service manual Controller SIGMA CONTROL 2 SCREW FLUID 1.1.3 9_9450 03USE...
  • Page 228 ➤ Close and lock the door of the equipment properly. ➤ Place the equipment as far as possible from the interfered radio or television receiver. Changes or modifications not expressly approved by KAESER could void the user's authority to operate the equipment.
  • Page 229 4 Design and Function The controller SIGMA CONTROL 2 controls, regulates, monitors, and protects the machine. All parameters needed to operate KAESER rotary screw compressors can be set and displayed using the controller. Various user-dependent password mechanisms protect the parameters. Components SIGMA CONTROL 2 has the following components: ■...
  • Page 230 Design and Function Operating panel ■ Optimum utilization of the drive motor in relation to the user's actual air demand. ■ Automatic restart of the machine after a power failure (can be deactivated). The monitoring function allows: ■ Supervision of all maintenance-relevant components via the maintenance interval counters. ■...
  • Page 231 Design and Function Operating panel Position Name Function «Left» Jumps to the left. Moves the cursor position to the next left field. «Up» Scrolls up the menu options. Increases a parameter value. «Information» Operating mode: Displays the event memory. «Acknowledgement» Confirms/acknowledges alarms and warning messages.
  • Page 232 Placing a suitable transponder in front of the RFID sensor field of the controller will automatically activate the communication between transponder and SIGMA CONTROL 2 . A suitable transponder is the KAESER RFID Equipment Card. Two of them have been provided with the machine.
  • Page 233 Design and Function Display Display Use the display to read information and to enter data. The display comprises 8 lines, each of 30 characters. During operation, the display will indicate the operating mode. Pressing «Enter» or one the arrow keys opens the main menu. Here, you can set the language to be used for the display of texts or open the various submenus.
  • Page 234 Design and Function Display 4.3.2 Main menu 8 9 p s i 0 8 : 1 5 1 7 6 ° F Language ········· Deutsch ········· Submenu ▶1 Status Submenu (shown here as the active line) ▶2 Performance data Submenu ▶3 Operating data Submenu ▶4 Maintenance...
  • Page 235 Design and Function Access rights Resetting current parameters Reset in the active line of In order to reset current parameters to Zero, activate the check box for the display. Reset will flash. First, press «Enter» to switch into setting mode. The check box You then press «UP».
  • Page 236 If you lose both Equipment Cards, you can register a new Equipment Card only after having en‐ tered the user name and the password. A new Equipment Card may be registered by KAESER Service subject to a fee, if the user name and the password are lost. Checking the machine status with KAESER CONNECT Using a PC with web browser, you can call up a visualization of your machine's controller and thus check the energy efficiency of the machine.
  • Page 237 You can switch from read mode to write mode to create a new user account, for example. ■ Closing KAESER CONNECT: ─ Logout function in the header. ■ Contact KAESER Service: ─ Display of authorized KAESER Service addresses. Fig. 8 Header Machine designation Logout Write mode Contact KAESER Service Menus – overview 4.6.1...
  • Page 238 Design and Function Menus – overview Machine model C o m p r e s s o r Part number and serial number of the machine PN : SN : Equipment number of the machine EN : MCS: Main Control System SIGMA CONTROL 2 MCS Part number and serial number of the controller PN :...
  • Page 239 Design and Function Menus – overview Main menu Navigation Function/submenu 1 Status ■ Messages ─ Status report ─ Current warnings Current faults ■ Statistics ■ Current pressure regulation ■ Current operating mode ■ DI/DO display ■ Diagram: Nominal pressure/airend discharge temper‐ ature <Status>...
  • Page 240 Design and Function Menus – overview Navigation Function/submenu 4 Maintenance ■ Oil filter ■ Oil separator ■ Oil change ■ Air filter ■ Valve inspection ■ Belts / coupling inspection ■ Bearing lubrication ■ Motor bearings ■ Electrical equipment ■ Annual maintenance <Configuration>...
  • Page 241 Design and Function Menus – overview 4.6.2.1 Status menu Navigation Function/submenu 1.1 Messages ■ Current messages ■ Message history (event memory) ─ Compressor messages ─ Diagnostic messages ─ System messages Status report Current warnings Current faults 1.2 Statistics ■ Overall load ■...
  • Page 242 Date format Time format Pressure unit Temperature unit Display illumination System data ■ SIGMA CONTROL 2 MCS: ─ Software ─ KAESER: Part number Serial number ─ Controller manufacturer: Part number Serial number Date of manufacture ■ Compressor: ─ Equipment number ─...
  • Page 243 Design and Function Menus – overview Navigation Function/submenu 5.4 Compressor start ■ Compressor ON ■ Compressor OFF Auto start Cut-in lock Start temperature 5.5 Acknowledgement Remote operation «Remote control» key Acknowledging the remote contact 5.6 ADT ■ AIR 1.00 Conduit correction ■...
  • Page 244 Design and Function Menus – overview Navigation Function/submenu 5.2.3 Load control ■ Set local mode ■ Set remote operation Activate/deactivate «Remote control» key ■ Timer operating mode pA/pB ■ Remote contact operating mode pA/pB ■ Assign load mode remote contact ■...
  • Page 245 Design and Function Menus – overview Navigation Function/submenu 5.7.4 Switch Configuring the switching points for pressure and temperature ■ System pressure pNloc ■ Internal pressure pi ■ Airend discharge temperature (ADT) ■ Inlet temperature ■ Compressed air outlet temperature (PD) Tab.
  • Page 246 Design and Function Menus – overview Navigation Function/submenu 8.2 Com-Module The following communications module may be used optionally: Profibus Modbus Modbus TCP DeviceNet Profinet <Com modules> menu are Details regarding the provided in tables 34, 35, 36, 37, 38. Tab. 33 Communication menu 4.6.2.4 COM module –...
  • Page 247 Design and Function Menus – overview Navigation Function 8.2 Com-Module Modbus TCP: Status COM module start Reset Bus fault Start time Time-out Use P settings IP address Subnet mask Gateway DNS Server 1 DNS Server 2 Tab. 36 Modbus TCP Navigation Function 8.2 Com-Module...
  • Page 248 Design and Function Menus – overview 4.6.2.5 Menu: Connections Navigation Function/submenu 8.1.2 Connections ■ SIGMA CONTROL 2 ─ Status ─ Mode: Master/Slave Port ─ IP address of communication partner ─ Communication alarm ■ Control technology ─ JSON-RPC active ─ IP address ─...
  • Page 249 Design and Function Operating modes and control modes 4.6.2.7 Menu: Power switching Navigation Function/submenu 10.1.1 Power switching ■ Star-delta start ─ Temperature, warm start ─ Star time at warm start Star time at cold start Star/Delta changeover time ─ Overload relay ─...
  • Page 250 Design and Function Operating modes and control modes ■ The drive motor is stopped. ■ The inlet valve is closed. ■ The minimum pressure/check valve shuts off the oil separator from the air distribution network. ■ The venting valve is open. The compressor motor starts as soon as system pressure is lower than the set point pressure (cut- off pressure).
  • Page 251 Design and Function Operating modes and control modes QUADRO Unlike the DUAL regulating mode, the machine will switch from LOAD to READY in QUADRO mode after periods with low compressed air consumption. After periods with a high compressed air consumption, the machine will switch from LOAD to READY after passing through IDLE.
  • Page 252 Design and Function Operating modes and control modes If the network pressure exceeds the TARGET value: Outside the frequency converter's range of control the machine reverts to the selected control mode. DUAL: The minimum controllable speed is reached and the machine switches to IDLE. The drive motor runs unloaded with low power consumption.
  • Page 253 Installation and Operating Conditions Maintaining ambient conditions 5 Installation and Operating Conditions Maintaining ambient conditions ➤ Follow the instructions in the machine's service manual. Installation conditions The installation and operating conditions depend the machine into which the controller is installed. UV radiation! Direct sunlight (UV radiation) can destroy the display screen.
  • Page 254 Installation Reporting Transport Damage 6 Installation Reporting Transport Damage 1. Check the machine for visible and hidden transport damage. 2. Inform the carrier and the manufacturer in writing of any damage without delay. Machine identification If the machine is run in sequenced operation its identification as detailed in the installation diagram is to be taken into account.
  • Page 255 7.2.1: Selecting menu options (introduction) ■ 7.2.2: Changing the display language ■ 7.2.3: Note the number of the KAESER Equipment Card ■ 7.2.4: Control access to SIGMA CONTROL 2 with the Equipment Card ■ 7.2.5: Generate password for SIGMA CONTROL 2 ■...
  • Page 256 Initial Start-up Configuring the controller Example: Select the > Configuration ➙ General > menu option Precondition The display shows the operating mode. 1. Press «Enter». The main menu is displayed. 2. Press the «UP» or «DOWN» key until Configuration is displayed as the active line. <...
  • Page 257 7.2.3 Noting the number of the KAESER Equipment Card user name displayed on the The number of your KAESER Equipment Card is identical to the SIGMA CONTROL 2 after you have successfully logged in using your Equipment Card. Fig. 9...
  • Page 258 Initial Start-up Configuring the controller If you have noted your user name and stored it in a suitable location, you can now generate a password on the SIGMA CONTROL 2. Note this generated password as well, and store it in a suit‐ able location.
  • Page 259 Initial Start-up Configuring the controller 5. Hold the Equipment Card in front of the controller's reader. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu Log-on successful. Prompt, whether the password is to be changed Password change with key ------------------------------ Name : E00019895...
  • Page 260 Initial Start-up Configuring the controller 3. Press «Enter» to switch into setting mode. A column with alphanumeric characters is displayed. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 7 User Name : E00019895 Password: **************** Active line [Login]...
  • Page 261 7.2.7 Generating a password for KAESER CONNECT You also need a password to access KAESER CONNECT for the SIGMA CONTROL 2. This password is also generated at the SIGMA CONTROL 2. Entering the password is necessary to ■...
  • Page 262 Initial Start-up Configuring the controller 3. Press the «DOWN» key repeatedly until the current time is displayed as the active line. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.1 General ▶1 System information ·········...
  • Page 263 Initial Start-up Configuring the controller 7. Use «UP» or «DOWN» to change the year setting. 8. Press «Enter» to save the settings. 9. Press «Esc» repeatedly to return to the Main Menu. 7.2.9 Setting display formats When setting the language, several display formats will automatically adjust to local usage. Setting the date format Select your preferred format.
  • Page 264 Initial Start-up Configuring the controller Precondition Password level 2 is activated, < Configuration> General > is selected (see 7.2.1). Menu Time format is displayed as the active line. 1. Press the «DOWN» key repeatedly until 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 265 Initial Start-up Configuring the controller 3. Change the unit with the «DOWN» or «UP» keys. 4. Press «Enter» to save the setting. 5. Press «Esc» repeatedly to return to the Main Menu. Setting the temperature display units Select your preferred display of the temperature unit: Format Example: °C...
  • Page 266 7.2.10 Setting and activating summer/winter time The system automatically switches between summer and winter time. Using KAESER CONNECT Using a PC with web browser, KAESER CONNECT enables you to view the following of the SIGMA CONTROL 2: ■ System status ■...
  • Page 267 Calling up KAESER CONNECT for SIGMA CONTROL 2 Precondition The password for KAESER CONNECT has already been generated, see chapter 7.2.7 The IP address of your controller is known. 1. Use an Ethernet cable to connect the PC and the SIGMA CONTROL 2.
  • Page 268 «Arrow key» Language selection Select a language Language selection window Selected language 7. Select the required language KAESER CONNECT is displayed in the selected language. 7.3.2 Displaying the system status Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. <System status> menu.
  • Page 269 Initial Start-up Using KAESER CONNECT Fig. 13 Status display <System status> menu Display SIGMA CONTROL 2 with status information 2. Check the status information. The entire local menu can be displayed at your PC. 1. Simply click in the display of the operating mode.
  • Page 270 ─ ─ IDLE ─ LOAD ■ Speed The display of the Speed is implemented only for machines with frequency converter. Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. Service manual Controller 9_9450 03USE SIGMA CONTROL 2 SCREW FLUID 1.1.3...
  • Page 271 Initial Start-up Using KAESER CONNECT 1. Select the <Graphs> menu. The system displays graphs. Fig. 16 Pressure/temperature graphs <Graphs> menu Speed System pressure Machine status Airend discharge temperature 2. Check pressure development 3. Check airend discharge temperature. 7.3.3.1 Zoom and arrow key functions Use the Zoom-in function to enlarge significant curve developments: Highlight a specific area within the graph by drawing a rectangle with the mouse pointer pressed.
  • Page 272 The following messages are shown: ■ Current messages ■ Compressor messages ■ System messages ■ Diagnostic messages Precondition KAESER CONNECT for SIGMA CONTROL 2 is displayed. <Messages> . 1. Open menu <Messages> is displayed. Menu Fig. 18 Messages < Messages > Menu System messages...
  • Page 273 User name: 6 to 16 characters, the second character must not be a number. ■ Password: 6 to 16 characters Precondition The generated password is available. KAESER CONNECT for SIGMA CONTROL 2 is displayed. <User administration> menu. 1. Select the <User administration> menu. The system displays the...
  • Page 274 Initial Start-up Using KAESER CONNECT Fig. 19 User administration menu <User administration> menu User list Activate write mode User account 2. Activate the write mode Log on for write access window opens. Fig. 20 "Log on for write access" window Log on for write access window «OK»...
  • Page 275 Initial Start-up Using KAESER CONNECT Fig. 21 Creating a new user <User administration> menu User type New user name Status Password «Add» key Confirm the password «Update» key Access level 6. Enter the new user name for an additional employee.
  • Page 276 3. Confirm the new password. 4. Click «Update» Result The existing user account has been updated. 7.3.7 Settings Settings via KAESER CONNECT apply only to your PC and your Browser. The following settings are available: ■ Units ■ Date format ■...
  • Page 277 Using KAESER CONNECT 7.3.8 Performing a data backup In order to use KAESER CONNECT to easily back up data from the SIGMA CONTROL 2 to your <Data backup> menu. own PC, use the You can choose to either perform a full backup or partial backups: ■...
  • Page 278 ➤ Click Logout. The logout message is displayed. Result You have closed KAESER CONNECT for SIGMA CONTROL 2. Adjusting the pressure parameters of the machine This section contains instructions for how to display and adjust the pressure parameters of the ma‐...
  • Page 279 Initial Start-up Adjusting the pressure parameters of the machine Parameter Explanation Setpoint Setpoint pressure can be regulated to two values: pA and pB pressure Setting: ■ Switching point pA or control pressure pA in machines with frequency converter (SFC) ■ Switching point pB or control pressure pB in machines with frequency converter (SFC) System...
  • Page 280 Initial Start-up Adjusting the pressure parameters of the machine Displaying compressor parameters Setpoint pressure is displayed. 1. Press «DOWN» repeatedly until 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.2 Pressure settings ·········...
  • Page 281 Initial Start-up Adjusting the pressure parameters of the machine 3. Press «Enter» to switch into setting mode. 116 psi parameter flashes. 4. Use «UP» or «DOWN» to adjust the system setpoint pressure pA. 5. Press «Enter» to accept the setting. 6.
  • Page 282 Initial Start-up Adjusting the pressure parameters of the machine Precondition Access level 2 is activated. < Configuration ➙ Pressure control ➙ Pressure settings > (see Section 7.4.1) 1. Select 2. Press the «DOWN» key repeatedly until the following is displayed as the active line: 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 283 Initial Start-up Adjusting the pressure parameters of the machine 2. Press «DOWN» repeatedly until the following is displayed: 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.2 Pressure settings Pressure rise Pressure increase pE SP : 122 psi ¦...
  • Page 284 Initial Start-up Configuring machine start and stop 4. Press «Enter» to save the setting. The «IDLE» key is deactivated. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.3 Load control pA/pB DO DOR1.04 ☐ ·········...
  • Page 285 Initial Start-up Configuring machine start and stop 2. Select < Compressor clock > . The display for setting the Compressor clock timing program appears. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 6 Compressor clock Compressor clock is activated Key clock : ☐...
  • Page 286 Initial Start-up Configuring machine start and stop 1. Press «DOWN» repeatedly until the 01 switching point is displayed as the active line. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 6 Compressor clock ·········...
  • Page 287 Initial Start-up Configuring machine start and stop 7.5.1.3 Activating the «Compressor timer» key Key clock is displayed as active line. 1. Press «UP» repeatedly until 2. Press «Enter» to switch into setting mode. The check box flashes in the active line. 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 288 Initial Start-up Configuring machine start and stop 5. Press the «UP» key. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.4.2 Compressor off Venting period : ☐ ········· Active line with deactivated check box Holidays : ☑...
  • Page 289 Initial Start-up Configuring machine start and stop 4. Press «Enter» to switch into setting mode. Key flashes. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.4.1 Compressor on Local mode : Key Active line Remote mode : Key ·········...
  • Page 290 Initial Start-up Configuring machine start and stop 5. Press the «UP» key. The activated check box is displayed. 6. Press «Enter» to save the setting. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.4.1 Compressor on Local mode : Key...
  • Page 291 Initial Start-up Configuring machine start and stop 7.5.4 Activating/deactivating the idle phase (Venting period function) After receiving the OFF signal from the remote control center, an additional idling phase (Venting period) can be activated before the machine is stopped completely. The duration of the idling phase can be timed and/or regulated by internal pressure.
  • Page 292 Initial Start-up Configuring machine start and stop 7.5.5 Activating/deactivating and adjusting the "Automatic restart after a power fail‐ ure" function 'Autostart:' is activated as standard. To avoid overloading the main power supply through several machines starting simultaneously, a delay period determining the restart of each machine can be entered. Overview ■...
  • Page 293 Initial Start-up Activating and adjusting the control modes 4. Press «Enter» to accept the setting. Activate the “Autostart” function in the same manner. 5. Press «Escape» repeatedly to return to the main menu. Result Automatic restart after a power failure is now deactivated. Setting up the automatic restart delay period If you operate several machines, it is better to start them in sequence.
  • Page 294 Initial Start-up Activating and adjusting the control modes 7.6.1 Selecting a control mode The following control modes are possible: ■ DUAL ■ QUADRO ■ VARIO ■ DYNAMIC ■ CONTINUOUS The standard setting of the control mode depends on the machine type. Precondition Password level 2 is activated.
  • Page 295 Initial Start-up Activating and adjusting the control modes 7.6.2 Adjusting the idle time of DUAL mode The machine is READY when the specified idle time has elapsed. The shorter the period, the more often the machine will switch from IDLE to READY. SIGMA CONTROL 2 will take into account the maximum motor switching capacity.
  • Page 296 Initial Start-up Activating the settings for the refrigerated dryer Precondition Password level 2 is activated. QUADRO control mode is selected. The display shows the operating mode. 1. Press «Enter». The main menu is displayed. < Configuration ➙ Control mode ➙ QUADRO > menu. 2.
  • Page 297 Activating the settings for the refrigerated dryer ■ Procedures following a fault of the refrigerated dryer: ─ Compressed air quality has priority Call KAESER Service immediately ■ Procedures following a fault of the refrigerated dryer: ─ Compressed air quantity has priority, Activate fault mode without refrigerated dryer ➤...
  • Page 298 Initial Start-up Activating the settings for the refrigerated dryer 6. Press «Enter» to accept the setting. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.9 Refrigeration dryer Control mode Compressor ready: Active line Timer Compressor Clk/RC/RB off: ·········...
  • Page 299 After a fault occurs in the refrigerated dryer, the SIGMA CONTROL 2 will shut the machine down. No compressed air is delivered. Because compressed air quality is decisive factor (dried compressed air), you must call KAESER Service immediately. An authorized KAESER service representative eliminates the fault and exe‐...
  • Page 300 Initial Start-up Activating the settings for the refrigerated dryer After a fault occurs in the refrigerated dryer, the SIGMA CONTROL 2 will shut the machine down. In order to ensure compressed air delivery for a defined period of time, the operator can activate the "fault mode without refrigerated dryer"...
  • Page 301 Initial Start-up Configuring the machine for local mode Result "Fault mode without refrigerated dryer" is activated. The compressor provides compressed air for connected consumers. The compressed air delivered in this mode contains a higher residual humidity because the func‐ tion of the refrigerated dryer is defective. Configuring the machine for local mode In local mode, the machine is regulated with the system setpoint pressure pA or pB.
  • Page 302 Initial Start-up Configuring the machine for local mode ■ Select the system setpoint pressure for the first switching point pA or pB. ■ Define further switching points. ■ Select the pA/pB Clock operating mode, see Section 7.8.3.3. When setting a clock program for the first time, note first the switching times on a sheet of paper.
  • Page 303 Initial Start-up Configuring the machine for local mode 3. Press «Enter» to switch into setting mode. n.a. flashes in the active line. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.3.1 pA/pB Clock ·········...
  • Page 304 Initial Start-up Configuring the machine for local mode 4. Press «Enter» to switch into setting mode. Reset check box flashes. 5. Press «UP». The check box is activated. 6. Press «Enter» to accept the settings. Result The clock program is now deleted. Selecting the operating mode 1.
  • Page 305 Initial Start-up Configuring the machine for local mode 4. Press «Enter» to accept the setting. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.3 Load control pA/pB Cycle Active line, manually set setpoint value – automati‐ pA : 10 h –...
  • Page 306 Initial Start-up Configuring the machine for master control 1. Press «UP» repeatedly until Local mode is displayed as the active line. 2. Press «Enter» to switch into setting mode. Operating mode flashes. 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 307 Initial Start-up Configuring the machine for master control Method Description Section Setpoint pressure pre-selection pA/pB remote contact: 7.9.7 An input contact provides the signal to switch from the system setpoint pressure pA to pB. Master control of compressors regulated On machines with the same FAD, 7.9.8.1 by pressure switch SIGMA CONTROL 2 controls the pressure...
  • Page 308 Initial Start-up Configuring the machine for master control Wiring the interface plug Fig. 26 Profibus plug wiring Terminal 1A Terminal 2B Terminal 1B Slide switch, terminating resistor Terminal 2A Service manual Controller 9_9450 03USE SIGMA CONTROL 2 SCREW FLUID 1.1.3...
  • Page 310 Initial Start-up Configuring the machine for master control 1. Connect the bus subscribers one after the other according to the pin assignment below. 2. Connect the screening to the plug housings at both ends. 3. Switch in the terminating resistor in the plugs of the first and last subscribers to the Profibus. Result The terminals for the remaining bus conduit (2A/2B) are switched off.
  • Page 311 Initial Start-up Configuring the machine for master control Proper removal of the plastic cover Fig. 28 Communication interface Designation of the interfaces Communication interface X4 (customer in‐ Rear side of the controller terface) SIGMA CONTROL 2 Plastic cover Ethernet interface X1 IO BUS X2 Communication interface X4 without plastic RS485–FC (USS interface) X3...
  • Page 312 Initial Start-up Configuring the machine for master control 1. Align the communication module. 2. Insert the communication module into the bay of interface X4 until it latches (see Fig. 29) The module is correctly installed when its front plate is seated solidly in the recess of the mod‐ ule bay.
  • Page 313 Initial Start-up Configuring the machine for master control 2. Select the < Communication ➙ Com-Module > menu. < Com-Module > menu is displayed. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 8.2 Com-Module Active line Status Counter 0 Com module not recognised...
  • Page 314 Initial Start-up Configuring the machine for master control After switching on the power supply, the bus alarm can be suppressed temporarily. ■ Settings for SIGMA AIR MANAGER without SIGMA AIR CONTROL PLUS ─ Start: 30 seconds ■ Settings for SIGMA AIR MANAGER with SIGMA AIR CONTROL PLUS ─...
  • Page 315 Initial Start-up Configuring the machine for master control 4. Press «Enter» to accept the setting. The communication module is activated. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 8.2 Com-Module Status counter 1 is displayed. Status Counter 1 No error ·········...
  • Page 316 Configuring the machine for master control The bus master can remotely control the SIGMA CONTROL 2. 7.9.3 Configuring the Profibus interface without SIGMA AIR MANAGER or VESIS Contact KAESER Service for information on configuring the Profibus interface if Profibus is to be used. Overview ■...
  • Page 317 Initial Start-up Configuring the machine for master control 5. Press «Enter». Status line is displayed as the active line. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 8.2 Com-Module Active line Status Counter 0 No error ------------------------------ Displayed communication module...
  • Page 318 Initial Start-up Configuring the machine for master control Example: Two machines with different delivery quantities Local operating mode of the master: Local mode pA/pB Clock. ■ Toggles between system pressure setpoints pA and pB by a clock program. ■ At peak load times, pressure is regulated to system set-point pressure pA. During periods of low air demand, pressure is regulated to system setpoint pB (e.g., at week‐...
  • Page 319 Initial Start-up Configuring the machine for master control Installing the Ethernet cable Use a cross-link Ethernet cable for the direct connection of two machines. Fig. 31 Direct connection of two SIGMA CONTROL 2 Controller machine 1 (Master mode) Controller machine 2 (Slave mode) Ethernet interface X1 Ethernet interface X1 Ethernet cable, cross-link cable...
  • Page 320 Initial Start-up Configuring the machine for master control Set the switching points pA and pB < Configuration ➙ Pressure control ➙ Pressure settings > menu. 1. Select the The switching point pA is displayed as the active line. 2. Press «Enter» to switch into setting mode. The display of switching point pA flashes.
  • Page 321 Initial Start-up Configuring the machine for master control Setting a clock program Setting the timer 1. Select the < Configuration ➙ Pressure 1. Select the < Configuration ➙ Pressure control ➙ Load control > menu. control ➙ Load control > menu. 2.
  • Page 322 Initial Start-up Configuring the machine for master control 7. Press «Enter» to accept the setting. 8. Press «DOWN» four times. 9. Press «Enter» to switch into setting mode. 10. Enter the IP address of the communication partner (slave). 11. Press «Enter» to accept the setting. 7.9.4.3 Configuring the controller of machine 2 as slave Precondition...
  • Page 323 Initial Start-up Configuring the machine for master control Example: ■ Controller machine 1 (Master mode): 169.254.100.101 ■ Controller machine 2 (Slave mode): 169.254.100.102 < Communication ➙ Ethernet ➙ IP configuration > . 1. Select 2. Enter IP address for the master. <...
  • Page 324 Initial Start-up Configuring the machine for master control 7.9.5.1 Making the electrical connection for remote LOAD contact Machine (example) Fig. 32 LOAD remote contact Electrical connection DI 1.12 LOAD remote contact closed (LOAD) LOAD remote contact open (IDLE) SIGMA AIR MANAGER BASIC contacts Electrical connection DI 1.12 ➤...
  • Page 325 Initial Start-up Configuring the machine for master control Assigning the input for LOAD remote contact The input for the LOAD remote contact is preassigned. Setting is only necessary if you deliberately want to use a different input. Load RC is displayed as the active line. 1.
  • Page 326 Initial Start-up Configuring the machine for master control 4. Press «Enter» to accept the setting. The «Remote control» key is activated and can be used. 5. Press the «Remote control» key to enable remote mode. 7.9.6 Configuring for master control with local/LOAD remote contact Overview ■...
  • Page 327 Initial Start-up Configuring the machine for master control Set local/LOAD remote contact operating mode: Remote mode is displayed as the active line. 1. Press «UP» repeatedly until 2. Press «Enter» to switch into setting mode. Remote mode flashes. 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 328 Initial Start-up Configuring the machine for master control 2. Press «Enter» to switch into setting mode. Setpoint pressure flashes. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.3 Load control Active line, current operating mode Local mode pB ·········...
  • Page 329 Initial Start-up Configuring the machine for master control Setting the LOAD remote contact operating mode Precondition Access level 2 is activated. < Configuration ➙ Pressure control ➙ Load control > menu is selected. Remote mode is displayed as the active line. 1.
  • Page 330 Initial Start-up Configuring the machine for master control ■ Assigning the remote contact input ■ Activating the «remote control» key ➤ Configure the setpoint pressure pre-selection as described. 7.9.7.1 Setting up remote contact mode pA/pB Precondition Password level 2 is activated, The electrical connections are made, <...
  • Page 331 Initial Start-up Configuring the machine for master control 7.9.7.3 Activating the «remote control» key Precondition Password level 2 is activated, < Configuration ➙ Pressure control ➙ Load control > is selected. Menu Key remote is displayed as the active line. 1.
  • Page 332 Initial Start-up Configuring the machine for master control ■ Assigning the floating relay contact ■ Setting local operating mode Establishing the electrical connection ■ Contact A open: SIGMA CONTROL 2 controls with system setpoint pressure pB ■ Contact A closed: SIGMA CONTROL 2 controls with system setpoint pressure pA ■...
  • Page 333 Initial Start-up Configuring the machine for master control 2. Press «Enter» to switch into setting mode. Setpoint pressure pA flashes. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.2 Pressure settings Setpoint pressure Active line pA SP : 124 psi ¦...
  • Page 334 Initial Start-up Configuring the machine for master control 2. Press «UP» repeatedly until Local mode is displayed as the active line. 3. Press «Enter» to switch into setting mode. Local operation display flashes. 8 9 p s i 1 7 6 ° F Menu 5.2.3 Load control Active line, current local operating mode...
  • Page 335 Initial Start-up Configuring the machine for master control Time period t1–t7: high compressed air demand Time period t8–t14: low compressed air demand t13: SK switches to IDLE. SK switches to IDLE. t14: BSD switches to IDLE. BSD switches to IDLE. Tab.
  • Page 336 Initial Start-up Configuring the machine for master control 5. Press «Enter» to accept the setting. 6. Adjust the switching differential in the same way. 7. If necessary, adjust the values for system setpoint pressure pB in the same manner. 8. Press «Esc» repeatedly to return to the Main Menu. Configuring the clock program The clock program for the example is set up using the following switching points: A maximum of 10 switching points are available:...
  • Page 337 Initial Start-up Configuring the machine for master control 5. Press «UP». The check box is activated. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.3.1 pA/pB Clock Active line, delete existing clock program Reset: ☒...
  • Page 338 Initial Start-up Configuring the machine for master control 7. Press «Enter» to accept the settings. The display stops flashing and the time (hours/minutes) is set. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Weekday setting.
  • Page 339 Initial Start-up Configuring the machine for master control 2. Press «Enter» to switch into setting mode. Local operation display flashes. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.2.3 Load control Active line Local mode pA/pB Clock Current local mode...
  • Page 340 Initial Start-up 7.10 Configuring email Weekday Time System set-point pressure Mon-Sun 12:00 pA On Mon-Sun 18:00 pB On Tab. 66 Example for a clock program for equal duty cycling during the day Variant C: Equal duty cycle during the week A timer triggers the switch between system set-point pressure pA and system set-point pressure pB (local operating mode: pA/pB SC2 Clk).
  • Page 341 1 7 6 ° F Menu 8.1.3 E-mail Active line; deactivate/activate email function active: ☐ Compressor number: 1 Setting the language Language: Deutsch ------------------------------ Sender address: status-kaeser@mdex.de 5. Set: ■ Compressor number ■ Language ■ Sender address ■ Sender's name ■...
  • Page 342 Initial Start-up 7.11 Configuring input and output signals Further setting options: ■ SMTP port ■ Timeout ■ Interval (repeats) Result The email functions are configured and activated. Suppress repeat messages (setting an interval) To suppress messages repeating at short intervals, a period of 0 – 900 minutes can be set during which a repeat of the same message is suppressed, i.e.
  • Page 343 Initial Start-up 7.11 Configuring input and output signals 7.11.1 Outputting important operational states of the machine Important operational machine states can be made available as a binary signal via floating con‐ tacts. Each output can be assigned only once. The following messages can be returned: Message Explanation Output...
  • Page 344 Initial Start-up 7.11 Configuring input and output signals 2. Press «Enter» to switch into setting mode. The display of the selected message flashes. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.7.1 DO functions Controller on Active line with assigned output DOR 1.05 ok ☑...
  • Page 345 Initial Start-up 7.11 Configuring input and output signals ■ The sensor has a measuring range of 0 – 50 m ■ The sensor is operated with 4–20 mA. 7.11.2.1 Selecting the Analog data menu Precondition Password level 2 is activated. The electrical connection is made.
  • Page 346 Initial Start-up 7.11 Configuring input and output signals 7.11.2.2 Editing sensor designation and unit of measure The display shows the line for the sensor designation as the active line. 1. Press «Enter» to switch into setting mode. 2. Use the «UP» and «DOWN» keys to select characters from the character set in order to assign a name to the sensor signal.
  • Page 347 Initial Start-up 7.11 Configuring input and output signals 4. Press «Enter» to accept the setting. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.7.2.2.5 AI_I_1 The line for sensor designation Volume flow 01. Active line AII 1.03 ☐...
  • Page 348 Initial Start-up 7.11 Configuring input and output signals 2. Press «Enter» to switch into setting mode. Quality range flashes. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.7.2.2.5 AI_I_1 The line for sensor designation Volume flow 01.
  • Page 349 Initial Start-up 7.11 Configuring input and output signals ■ Assign and activate the input ■ Set the time delay ■ Set the logic ■ Assign and activate the output ■ Select the message type (operational, fault, warning) ■ Activate the message. 7.11.3.1 Selecting the <...
  • Page 350 Initial Start-up 7.11 Configuring input and output signals 2. Press «Enter» to switch into setting mode. Input flashes. 3. Select the relevant input with the «UP» or «DOWN» keys. 4. Press «Enter» to accept the setting. 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 351 Initial Start-up 7.11 Configuring input and output signals 7.11.3.5 Setting the logic Possible logic settings Message at Symbol 24 V Tab. 69 Logic 1. Press the «Right» key once. 2. Press «Enter» to switch into the logic setting mode. Logic display flashes. 3.
  • Page 352 Initial Start-up 7.12 Activating remote acknowledgement 8. Press «Enter» to accept the setting. ok is displayed. The output is assigned and activated. 7.11.3.7 Selecting the message type (operational, alarm, warning) 1. Press «DOWN» once until message type is displayed as the active line. 2.
  • Page 353 Initial Start-up 7.12 Activating remote acknowledgement 7.12.1 Selecting the < Configuration ➙ Acknowledgement > menu Precondition Access level 2 is activated. 1. In operating mode, switch to the main menu with the «Enter» key. < Configuration ➙ Acknowledgement > menu. 2.
  • Page 354 Initial Start-up 7.12 Activating remote acknowledgement 3. Press «UP». 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.5 Acknowledgement Remote mode : Key+RC Active line with activated check box for the Remote Key remote : ☑...
  • Page 355 Initial Start-up 7.13 Linking to an external pressure transducer 8. Press «Enter» to accept the setting. ok is displayed, the input is assigned and activated. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 5.5 Acknowledgement Remote mode : Key+RC...
  • Page 356 Initial Start-up 7.13 Linking to an external pressure transducer 7.13.1 Selecting the < Configuration ➙ Pressure control > menu Precondition Access level 2 is activated. 1. In operating mode, switch to the main menu with the «Enter» key. < Configuration ➙ Pressure control > menu. 2.
  • Page 357 Initial Start-up 7.14 Commissioning the machine 3. Press «Enter» to accept the setting. Input AII (analog value via frequency converter) is displayed. 4. Press «DOWN» once. The line for activating the input is displayed. 5. Press the «Right» key. 6. Press «Enter» to switch into setting mode. check box flashes.
  • Page 358 Initial Start-up 7.14 Commissioning the machine 1. Check and confirm all the items in the checklist before starting the machine. When power is applied to the machine the controller boots and carries out a self test. Controller on LED illuminate. The display and the The actual system pressure (pNloc), the time and the airend discharge temperature are dis‐...
  • Page 359 Operation Switching on and off 8 Operation Switching on and off Always switch the machine on with the «ON» key and off with the «OFF» key. A power supply disconnecting device should be installed by the user. Fig. 36 Switching on and off Machine ON LED «LOAD/IDLE»...
  • Page 360 Operation Switching off in an emergency and switching on again Result Controller voltage LED extinguishes. The machine is switched off and disconnected from the power supply. In rare cases, if you need to shut the machine down immediately and cannot wait until the automatic shut-down process is finished: ➤...
  • Page 361 Operation Acknowledging alarm and warning messages ■ Message going: LED flashes ■ Message acknowledged: LED off Fig. 38 Acknowledging messages Warning LED (yellow) Alarm LED (red) «Acknowledge» key Alarm message Alarm LED flashes red. An alarm shuts the machine down automatically. The The system displays the appropriate message.
  • Page 362 Operation Displaying messages Displaying messages < Status ➙ Messages > menu: The following information can be called up in the ■ Current messages ─ Last fault ─ Last warning ─ Number of currently registered fault and/or warnings ■ The message history stores the last 1000 events, these include fault and warning messages. ─...
  • Page 363 Operation Displaying messages 8.4.1 Selecting the Status menu 1. In operating mode, switch to the main menu with the «Enter» key. < Status ➙ Messages > menu. 2. Select the <messages> menu is displayed. The number of current faults and warnings is displayed in the two bottom lines. 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 364 Operation Displaying the current operating mode 3. Press «Enter». <compressor messages> menu is displayed. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 1.1.2.1 Compressor messages Last compressor message 0021 S q 16.04.13 13:32:49 Message text for fault message 0021 Refrigeration dryer T ⇟...
  • Page 365 Operation Adjusting working pressure 4. Press «Enter». < Current operating mode > submenu is displayed. 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 1.4 Current operating mode Active line Compressor on Key Load control pA ·········...
  • Page 366 Operation Displaying analog data Displaying analog data < Performance data > menu option: The following information can be called up in the ■ Local system pressure ■ Airend discharge temperature Rise rate, airend discharge temperature ■ Differential pressure, oil separator cartridge ■...
  • Page 367 Operation Displaying operating data Displaying operating data <Operating data> menu option: The following information can be called up in the <Operating hours> ■ ─ Compressor: Total machine running time ─ Load run: Machine running time in LOAD mode ─ Compressor motor: Running time of compressor motor (adjustable) ─...
  • Page 368 Operation Displaying operating data 3. Press «Enter» to switch into setting mode. The display of the running time flashes (e.g., 3050h ). 8 9 p s i 0 8 : 1 5 1 7 6 ° F Menu 3.1 Operating hours Compressor 3050 h On load 3030 h Motor 3050 h...
  • Page 369 Operation Displaying operating data Message Meaning 0010 O The power supply is connected. Controller on The controller is powered. 0011 O The machine can be switched on although the machine tempera‐ ture is below the permissible starting temperature. Cold start release The machine can be switched on only as long as the message is displayed.
  • Page 370 Operation Setting the maintenance interval Message Meaning 0094 O T-Switch ADT 0095 O p-Switch pN 0200 O The internal voltage monitoring reports low voltage fault IOSlot1 IOSlot1 Undervoltage error 50 0201 O The internal voltage monitoring reports low voltage fault IOSlot2 IOSlot2 Undervoltage error 50 0202 O The internal voltage monitoring reports low voltage fault IOSlot3...
  • Page 371 Operation 8.10 Safety relief valve checking 3. Press «DOWN» repeatedly until the maintenance interval for Oil change is displayed as the ac‐ tive line. 8 9 p s i 0 8 : 1 5 1 7 6 ° F 4 Maintenance Oil separator 3000 h ¦...
  • Page 372 Operation 8.10 Safety relief valve checking 5. In operating mode, switch to the main menu with the «Enter» key. 6. Select the < Machine test ➙ TÜV inspection > menu. Pressure relief valve is displayed as the active line. 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 373 Operation 8.11 Checking the temperature sensor and overheating shutdown function If the alarm message pRV ⇞ appears, the safety relief valve is defective. The permissible internal pressure was exceeded by 30 psi. ➤ Have the safety relief valve replaced. Avoid oil mist: ➤...
  • Page 374 The machine will switch off as soon as the airend discharge temperature attains a value of 226 °F . The machine does not shut down? ➤ Abort the test and contact KAESER Service as soon as possible. Correct conclusion of the test 1. Press «Enter» to switch into setting mode.
  • Page 375 Operation 8.11 Checking the temperature sensor and overheating shutdown function 3. Press «Enter» to accept the setting. The offset is reset to 32 °F . The test mode is deactivated and the test is completed. 4. Press «Escape» repeatedly to return to the main menu. Resetting SIGMA CONTROL 2 will display the highest measured value if the test for switching off at overtem‐...
  • Page 376 1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorized KAESER service representative. Interpreting alarm messages If an input signal is classified as an alarm, the controller will display the alarm upon the sig‐...
  • Page 377 Fault Recognition and Rectification Interpreting alarm messages Message Possible cause Remedy 0005 A Maximum air temperature at Check the line to the Oil separator Temperature ⇞ the oil separator tank outlet trip relay. is exceeded. 0007 A Fault in main power supply. Have the main power Power supply monitor supply checked.
  • Page 378 Message Possible cause Remedy 0021 A Refrigerated dryer: Contact Refrigeration dryer T ⇟ Compressed air tempera‐ KAESER Service. ture too low. 0022 A Oil separator cartridge clog‐ Change the oil sepa‐ Oil separator Δp ⇞ ged. rator cartridge. 0023 A Drive motor bearings over‐...
  • Page 379 Check condensate fective. drain and conden‐ sate conduits. 0057 A Compressor model uncer‐ Contact Model? tain. KAESER Service. 0058 A The condensate drain is de‐ Check condensate Condensate drain fective. drain and conden‐ sate conduits. 0059 A Drive belt or coupling bro‐...
  • Page 380 Oil-/air cooler fan Overcurrent first fan motor. shut-down. Reset the overload relay. 0200 A Frequency converter fault Contact Compressor motor USS alarm KAESER Service. 0201 A Frequency converter fault Contact Compressor motor USS alarm KAESER Service. 0202 A Frequency converter fault Contact Compressor motor USS alarm KAESER Service.
  • Page 381 Diagnostic messages are identified with the letter D. They provide information on the status of the controller, the connected input and output modules, and support KAESER service with troubleshooting. Interpreting warning messages If an input signal is classified as a warning, the controller will display the warning upon the signal's arrival.
  • Page 382 Oil separator cartridge clogged. 0007 W Drive motor bearing de‐ Contact KAESER Service. Motor bearings fective. 0008 W Maximum airend dis‐ Clean the cooler. Airend discharge temperature ADT ↑ charge temperature will Check the cooling oil level.
  • Page 383 Fault Recognition and Rectification Interpreting warning messages Message Possible cause Remedy 0031 W Motor bearing of com‐ Contact KAESER Service. Motor bearings h ⇞ pressor motor: Maintenance interval has elapsed. 0032 W Electric components and Inspect and reset the mainte‐...
  • Page 384 Keep ambient conditions Start temperature ↓ is too low (< 35°F). within specified limits. 0061 W The airend discharge Contact KAESER Service. Compressor T ↓ temperature (ADT) did not reach the minimum value within the speci‐ fied time. 0066 W...
  • Page 385 Fault Recognition and Rectification Interpreting warning messages Message Possible cause Remedy 0072 W Refrigerated dryer: Check condensate drainage RD condensate drain The condensate drain is defective. 0081 W 0082 W 0083 W 0084 W 0085 W 0086 W 0087 W 0088 W 0089 W 0090 W...
  • Page 386 Maintenance 10.1 Maintenance Work 10 Maintenance 10.1 Maintenance Work The SIGMA CONTROL 2 and the I/O modules are maintenance-free. Use basic safety instructions and safety instructions for working on live components. Service manual Controller 9_9450 03USE SIGMA CONTROL 2 SCREW FLUID 1.1.3...
  • Page 387 Your advantage: lower costs and higher compressed air availability. 11.3 Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.4 Displaying the version number, machine model, part number and serial number 1. In operating mode, switch to the main menu with the «Enter» key.
  • Page 388 0 8 : 1 5 1 7 6 ° F Menu 5.1.1.1 SIGMA CONTROL 2 MCS Software Software 1.1.3 ········· Kaeser Part number PN 7.7601.0 Serial number x.xx.xx ········· 4. Keep pressing the «DOWN» key to display further settings. 8 9 p s i 0 8 : 1 5 1 7 6 °...
  • Page 389 Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning ➤ Follow the instructions in the machine's service manual. 12.2 Packing ➤ Follow the instructions in the machine's service manual. 12.3 Storage ➤ Follow the instructions in the machine's service manual. 12.4 Transporting ➤...
  • 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 Spare parts 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.kaeser.com...
  • Page 392 /KKW/GBASE 1.00 en ERSATZTEILE 10357405_10 ESD.2C 20130903 115349...
  • Page 393 Contents Safety and Responsibility Safely dealing with sources of danger ................Spares for service and repair ................... ESD 442 SFC / 14 bar ....................Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E...
  • Page 394 Contents 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 Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E...
  • Page 396 List of Illustrations Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E...
  • Page 397 List of Tables Tab. 1 Advise others that the machine is being serviced..............Tab. 2 Machine data ..........................Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E...
  • Page 398 List of Tables Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E...
  • Page 399 ➤ Do not carry out welding, heat treatment or mechanical modifications on pressurised compo‐ nents (e.g. pipes and vessels) as this influences the component's resistance to pressure. The safety of the machine is then no longer ensured. Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E...
  • Page 400 Unsuitable spare parts Unsuitable spare parts compromise the safety of the machine. ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER replacement parts on pressure bearing parts. Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205...
  • Page 401 When ordering spare parts for a component, please indicat the material and serial numbers of the machine and the position number and designation of the spare parts. ESD 442 SFC / 14 bar Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E...
  • Page 403 Safety and Responsibility ESD 442 SFC / 14 bar Spare parts Screw compressor ESD 442 SFC / 14 bar ESD.2C / 1204/1205 No.: TTL-ESD_2C_10357405_10_00 E...
  • Page 404 Safety and Responsibility ESD 442 SFC / 14 bar 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 Test report to EN 10204 Customer: Linde Kryotechnik AG Dättlikonerstrasse 5 8422 Pfungen Machine : 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...
  • Page 407 KAESER KOMPRESSOREN AG P.O.Box 2143 • 96410 Coburg • Germany • Phone +49 9561 6400 Fax +49 9561 640130 Gas inlet Gas suction Outlet Mass Total power Frequency temperature pressure pressure throughput consumption 20 Hz 299,1 K 1,05 bar (abs)
  • Page 408 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 7. Measurement record for units with suction side gas supply...
  • Page 409 Helium unit Measurement record for helium screw compressor units ESD 442 SFC 14,0 bar(a) HE a.c. /480V 60Hz / 1205 - Linde CH, Proj. Florence12, USA Compressor unit Type/Serial-No.: ESD.2C 4824071 Mat.No.: Equipment-No.: Sigma 38 Helium / 1014 EQ.-No. 788085 Airend Type/Serial-No.:...
  • Page 410 Helium unit Measurement record for helium screw compressor units ESD 442 SFC 14,0 bar(a) HE a.c. /480V 60Hz / 1205 - Linde CH, Proj. Florence12, USA Compressor unit Type/Serial-No.: ESD.2C 4824071 Mat.No.: Equipment-No.: Sigma 38 Helium / 1014 EQ.-No. 788085 Airend Type/Serial-No.:...
  • Page 411 Helium unit Measurement record for helium screw compressor units ESD 442 SFC 14,0 bar(a) HE a.c. /480V 60Hz / 1205 - Linde CH, Proj. Florence12, USA Compressor unit Type/Serial-No.: ESD.2C 4824071 Mat.No.: Equipment-No.: Sigma 38 Helium / 1014 EQ.-No. 788085 Airend Type/Serial-No.:...
  • 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 204876.0 Female rotor 204866.00010 GGG 50 These components were manufactured to KAESER works drawings and tested to KAESER quality standards. The quality (dimensions, surface finish, material) complies with requirements. We hereby certify that the above named equipment/part complies with regulations.

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