3.10 Environmental Protection ....................Design and Function Enclosure ......................... Function ........................... Floating relay contacts ..................... Remote LOAD-IDLE control ..................... Options ..........................4.5.1 Machine mountings ..................... Operating modes and control modes ................Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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13.1 Pipeline and instrument flow diagram (P+I diagram) ............13.2 Pipe and Instrument Flow Diagram (P&I diagram): MODULATING control mode ... 13.3 Dimensional Drawing ....................... 13.4 Electrical Diagram ......................Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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Contents Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
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Fig. 26 Changing the oil filter ........................Fig. 27 Changing the oil separator cartridge ..................Fig. 28 Transporting with a forklift truck ....................Fig. 29 Transporting with a crane ......................Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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List of Illustrations Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
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Cooling oil changing intervals ..................... Tab. 44 Regular service tasks ......................... Tab. 45 Permissible cooling oil level under LOAD ................. Tab. 46 Logged maintenance tasks ......................Tab. 47 Consumable parts ........................Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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List of Tables Service Manual Screw Compressor viii SX SIGMA CONTROL BASIC 9_6919 04 E...
The possible consequences of ignoring a warning are shown here. The word "Danger" indicates that death or severe injury can result from ignoring the instruction. ➤ The measures required to protect yourself from danger are shown here. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
The cause is named in the help text ... ➤ ... and a remedy given. This symbol refers to important information or measures concerning environmental protection. Further information Here, your attention is drawn to further topics. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Transformer power supply for refrigeration dryer Refrigeration dryer Tab. 3 Options Weight The weight given is the maximum. The actual weights of individual machines are dependent on equipment fitted. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
1 see figure 1 see figure 1 see figure 1 ty of inlet air * Higher altitudes are permissible only after consultation with the manufacturer. Tab. 6 Ambient conditions Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
8 [m Extractor for forced venti‐ 1000 1200 1500 2000 lation: Flow rate [m /h] at 100 Pa Tab. 8 Ventilation (60Hz) Pressure Maximum working pressure: see nameplate Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Cooling Oil Recommendation A sticker showing the type of oil used is located near the oil separator tank filler. Information on ordering cooling oil is found in chapter 11. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Highest permissible sys‐ 0.16 0.39 0.23 0.18 tem impedance* [Ohm] *Specification related to the sum of impedences in exterior and neutral liner. Tab. 22 Supply conditions at 400V/3/50Hz Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
This is, for example, nationally applied European directives and/or valid national legislation, safety and accident prevention regulations. ➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐ nance of the machine. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
The user must ensure that the cooling oil is changed as required or at least annually and the oil change must be documented. This requirement may be waived if an oil analysis proves that the oil is still usable. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
➤ Close shut-off valves or otherwise isolate the machine from the air main to ensure that no com‐ pressed air can flow back into the machine. ➤ Vent all pressurized components and chambers completely. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
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➤ Follow safety regulations when dealing with lubricants and chemical substances. ➤ Avoid contact with skin and eyes. ➤ Do not inhale oil mist or vapour. ➤ Do not eat or drink while handling cooling and lubricating fluids. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
■ inlet air free of explosive or chemically unstable gases or vapours, ■ inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sulphide. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
➤ 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 chapter4, section 4.7. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Incorrect oil levels can cause damage to the machine or excessive oil content in the compressed air. ➤ Check the oil level regularly and correct as necessary. Tab. 29 Safety Signs Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
■ incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
➤ Observe relevant national regulations. This applies particularly to parts contaminated with cooling oil. ➤ Do not allow cooling oil to escape to the environment or into the sewage system. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Safe and reliable operation is only assured with the enclosure closed. Access doors are hinged to swing open and removable panels can be lifted off. Latches are released by a key supplied with the machine. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Floating relay contacts Floating relay contacts are provided for the transfer of signals, messages. Information on location, loading capacity and type of message or signal is found in the electrical diagram. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
The options available for your machine are described below. 4.5.1 Option H1 Machine mountings These mountings allow the machine to be anchored firmly to the floor. Fig. 5 Machine mountings Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Machine for basic load in a compressed air station QUADRO Tab. 30 Energy-efficient control modes The SIGMA CONTROL BASIC control unit is factory set to QUADRO control mode unless specifically ordered otherwise. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
The machine will stop automatically if a door or panel fitted with these safety interlocks is opened or removed. ■ Enclosures and guards for moving parts and electrical connections: These protect against accidental contact. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Exits the edit mode without saving. «enter» Enters edit mode. Exits the edit mode and saves. Only affects the value in the third line of the display. Tab. 32 Keys Fig. 7 Indicators Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Only KAESER Service has the right to change these parameters. Load hours counter Shows the total time the drive motor has run under LOAD. Only KAESER Service has the right to change these parameters. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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The switching differential determines the difference between cut-in pressure and cut-out pressure (system pressure setpoint: switching point) and therefore the switching fre‐ quency from LOAD to IDLE. Range of adjustment [bar]: -0.1 ... −5.0 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
4.9.3 Messages Alarm message An alarm shuts the machine down automatically. The red LED flashes (figure 7). Warning message The yellow LED lights to indicate a warning (figure 7). Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
The distances quoted are recommended distances and ensure unhindered access to all ma‐ chine parts. ➤ Please consult KAESER if they cannot be kept to. Precondition The floor must be level, firm and capable of bearing the weight of the machine. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
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 cooling. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
To ensure the desired air quality when charging a vented air network, we recommend the installation of an air main charging system. ➤ Consult KAESER for advice on this subject. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
1. Check the machine for visible and hidden transport damage. 2. Inform the carrier and the manufacturer in writing of any damage without delay. Making the Compressed Air Connection Precondition The compressed air system is vented completely. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is present. 7. Connect the machine to the power supply. Further information The electrical diagram 13.4 contains further details of the power supply connection. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Option H1 Anchoring the machine ➤ Use appropriate fixing bolts to anchor the machine. Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.3. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Details of dangers and their avoidance are found in chapter 3.5. Instructions to be Observed before before Every Start-Up Incorrect or improper start-up can cause injury to persons and damage to the machine. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
➤ Are door interlock switches aligned and their function checked? ➤ Are all access doors closed and latched and all removable panels in – place and secured? Tab. 37 Installation conditions checklist Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Chapter 10.14 provides detailed information on how to drain cooling oil from the oil separator tank. Material 0.25 l Cooling oil Precondition The supply disconnecting device is switched off, the device is locked off, the absence of voltage has been verified. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
3. Press the «ON» key. The green Machine ON LED lights continuously. The drive motor runs up and after a short time the machine switches to LOAD and delivers com‐ pressed air. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
1. Open the access panel while the machine is running. The machine shuts down automatically. The controller displays an alarm message. 2. Close the panel and acknowledge the alarm. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
3. 2. Press and hold «enter» for at least 3 seconds until the cursor flashes. 3. Use the arrow keys to set the desired differential and confirm with «enter». Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut- out pressure). 8.1.2 Switching off Depending on current operating condition, the machine shuts down after a protective run-on period. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
1. Turn the EMERGENCY STOP pushbutton in the direction of the arrow to unlatch it. 2. Press the reset key to reset any alarm messages. The machine can now be started again. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Warning LED extinguishes as soon as the cause of the warning is rectified. Setting parameters If a password is needed it is requested automatically. Every action can be cancelled with the «escape» key. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
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2. Repeat until all characters have been entered. When the correct password is entered the parameters are displayed. 3. Use the «UP»/«DOWN» keys to change the value of the parameter and confirm with «enter». Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
➤ Have the frequency converter ■ drive belts parted checked by an authorized KAESER Service Technician. ■ compressor not venting correctly atSTANDSTILL. ■ Back-pressure switch defective Brief interruption of power supply. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Oil level in the oil separator tank Drain off oil until the correct level too high. is reached. Oil return line clogged. Check dirt trap in the return line. Tab. 41 Other faults and actions Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
2. Do not open the cabinet while the machine is switched on. Further information Details of authorized personnel are found in chapter 3.4.2. Details of dangers and their avoidance are found in chapter 3.5. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Interval Maintenance task see chapter Weekly Check the cooling oil level. 10.9 Cooler: 10.3 Check the filter mat. Control cabinet: 10.4 Check the filter mat. h = operating hours Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
3 000/1 2 000/1 * Cool to moderate ambient temperatures, low humidity, high duty cycle ** Changing intervals of >6000 operating hours are not permissible without an oil analysis. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
The filter mats help to keep the cooler clean. If the filter mats are clogged, adequate cooling of the components is no longer ensured. Material Filter mats: Warm water and household detergent Spare parts (as required) Precondition The machine is switched off. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
The power supply disconnecting (isolating) device is switched off, the disconnect device is locked in the off position, a check has been made that no voltage is present. The machine has cooled down. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
The power supply disconnecting (isolating) device is switched off, the disconnect device is locked in the off position, a check has been made that no voltage is present. The machine has cooled down. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
The power supply disconnecting (isolating) device is switched off, the disconnect device is locked in the off position, a check has been made that no voltage is present. The machine has cooled down. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Make a visual check for damage. 1. Turn the pulley by hand so that all of the belt can be inspected for damage. 2. Change the belts immediately if any damage is found. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Operating state Minimum oil level Maximum oil level LOAD Tab. 45 Permissible cooling oil level under LOAD Precondition The machine has been running at least 5 minutes under LOAD. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
«enter» key for at least three seconds. 4. Enter the password "BASIC" and confirm with the «enter» key. 5. Use the arrow keys to select parameter "on" and confirm. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
The oil circulation vents automatically as soon as the machine is stopped. Venting takes place in three stages: ■ Isolate the compressor from the air system. ■ Vent the oil separator tank. ■ Manually vent the air cooler. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
➤ Do not direct the maintenance hose at persons while venting. ➤ Do not inhale the oil mist. ➤ Check that the oil separator tank pressure gauge reads 0 bar. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Precondition The power supply disconnecting (isolating) device is switched off, the disconnect device is locked in the off position, a check has been made that no voltage is present. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Isolate the machine from the air system. ➤ Close the user's shut-off valve between the machine and the air system. If no shut-off valve is provided, the complete air system must be vented. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
2. Open the user's shut-off valve between the machine and the air system. 3. After about 10 minutes, check the oil level again and top up if necessary. 4. Switch off the machine and visually check for leaks. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
➤ Dispose of used oil in accordance with environmental protection regulations. Draining the oil from the cooler Fig. 25 Changing the cooling oil, oil cooler Oil cooler Male hose fitting Hose coupling (oil drainage) Shut-off valve Shut-off valve Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
The machine is fully vented, the pressure gauge on the oil separator tank reads 0 bar. WARNING There is risk of burns from hot components and oil. ➤ Wear long-sleeved clothing and gloves. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
─ Oil filter ─ Air filter All the cooling oil has run out of the separator cartridge 1–2 minutes after shutting down. A cooling oil receptacle is not needed. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
2. Open the user's shut-off valve between the machine and the compressed air network. 3. Switch on the power supply and reset the maintenance interval counter. 4. Stop the machine after 10 minutes and visually check for leaks. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Document 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. 46 Logged maintenance tasks Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
■ the security of genuine KAESER spare parts, ■ increased legal certainty as all regulations are kept to. ➤ Why not sign a KAESER AIR SERVICE maintenance agreement! Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
➤ Make sure that any service or repair tasks not described in this manual are carried out by an authorized KAESER service representative. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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Spares, Operating Materials, Service 11.5 Spare Parts for Service and Repair Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
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Spares, Operating Materials, Service 11.5 Spare Parts for Service and Repair Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator tank. Frozen moisture can damage components, diaphragms, valves and gaskets. Advice can be obtained from KAESER on storage and commissioning. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Attached components such as cyclone separators, condensate drains or filters ■ Rain protection covers Precondition The lifting gear complies with local safety regulations. No pressure should bear on the sides of the machine cabinet. Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
Machines with refrigeration dryers The sealed refrigerant circuit still contains both refrigerant and oil. ➤ Refrigerant and oil must be drained and disposed of by an authorized body. Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
Annex 13.2 Pipe and Instrument Flow Diagram (P&I diagram): MODULATING control mode 13.2 Option C1 Pipe and Instrument Flow Diagram (P&I diagram): MODULATING control mode Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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Annex 13.2 Pipe and Instrument Flow Diagram (P&I diagram): MODULATING control mode Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
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Annex 13.2 Pipe and Instrument Flow Diagram (P&I diagram): MODULATING control mode Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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Annex 13.2 Pipe and Instrument Flow Diagram (P&I diagram): MODULATING control mode Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...
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Annex 13.2 Pipe and Instrument Flow Diagram (P&I diagram): MODULATING control mode Service Manual Screw Compressor 9_6919 04 E SX SIGMA CONTROL BASIC...
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Annex 13.2 Pipe and Instrument Flow Diagram (P&I diagram): MODULATING control mode Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...