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KAESER KOMPRESSOREN Manuals
Air Compressor
FSD SIGMA CONTROL 2
Service manual
KAESER KOMPRESSOREN FSD SIGMA CONTROL 2 Service Manual
Screw compressor
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Contents
Table of Contents
Bookmarks
Table of Contents
Table of Contents
Using this Document
Further Documents
Copyright
Symbols and Labels
Warnings
Tab. 1 Danger Levels and Their Definition (Personal Injury)
Potential Damage Warnings
Other Alerts and Their Symbols
Tab. 2 Danger Levels and Their Definition (Damage to Property)
Technical Specifications Nameplate
Optional Accessories
Weight
Tab. 3 Nameplate
Tab.4 Optional Accessories
Select Temperature
Ambient Conditions
Tab. 5 Machine Weight
Tab. 6 Select T Emperature
Tab. 7 Ambient Conditions
Ventilation
Fig.1 Maximum Relative Humidity of Intake Air
Tab. 8 Overview Ventilation (50 Hz)
Pressure
Delivery
Tab. 9 Overview Ventilation (60 Hz)
Tab. 10 Pressure Relief Valve Activating Pressure (50Hz)
Tab. 11 Pressure Relief Valve Activating Pressure (60Hz)
Cooling Oil Recommendation
Tab. 12 FAD (50 Hz)
Tab. 13 FAD (60 Hz)
Tab.14 Cooling Oil Recommendation
Tab. 15 Cooling Oil Recommendation (Food Processing)
Cooling Oil Charge
Motors and Power
Compressor Drive Motor
Fan Motor
Tab. 20 Compressor Drive Motor
Tab. 21 Compressor Motor (60Hz)
Fan Motor
Tab. 22 Fan Motor (Option K1)
Tab. 23 Fan Motor (Option K1. 60Hz)
Tab. 24 Fan Motor (Option K2. 50Hz)
Tab. 25 Fan Motor (Option K2. 60Hz)
Noise Emission
Powersupply
Power Supply Specifications
Tab. 26 Noise Emission
Tab. 27 Noise Emission
Mains Frequency: 50 Hz
Mains Frequency: 60 Hz
Water Cooling
Design Data
Cooling Water Quality
Available Heat Capacity
Tab. 35 Cooling Water Quality
Tab. 36 Heat Capacity (Option W1)
Safety and Responsibility
Basic Instructions
Specified Use
Improper Use
User's Responsibilities
Observe Statutory and Universally Accepted Regulations
Determining Personnel
Adherence to Inspection Schedules and Accident Prevention Regulations
Dangers
Safely Dealing with Sources of Danger
Tab.37 Inspection Intervals According to Ordinance on Industrial Safety and Health
Safe Machine Operation
Organisational Measures
Danger Areas
Safety Devices
Safety Signs
Fig.2 Location of Safety Signs
Emergency Situations
Correct Fire Fighting
Tab. 39 Safety Signs
Treating Injuries from Handling Cooling Oil
Warranty
Environment Protection
Design and Function Enclosure
Machine Function
Fig.3 Enclosure Overview
Floating Relay Contacts
Fig.4 Machine Layout
Options
Machine Mountings
Water-Cooling
Cooling Air Filter Mat
Fig.5 Machine Mountings
Fig.6 Water-Cooling (Option K2)
Prepared Tor Extemal He at Recovery
Control Air Connection Tor Modulating Control
Fig.7 Cooling Air Filter Mat (Option K3)
Operating Modes and Control Modes
Operating Modes
Control Modes
Safety Devices
Operating Panel SIGMA CONTROL 2
Fig.8 Keys
Fig.9 Indicators
Tab.42 Buttons
Fig.10 RFID Sensor Field
Tab. 43 Displays
Installation and Operating Conditions
Ensuring Safety
Installation Conditions
Determining Loeation and Clearances
Ensuring the Machine Room Ventilation
Fig.11 Recommended Machine Placement and Dimensions [MM]
Exhaust Duct Design
Operating the Machine in a Compressed Air Network
Installation
Ensuring Safety
Reporting Transport Damage
Connecting the Machine with the Compressed Air Network
Connecting the Power Supply
Fig.12 Compressed Air Pipework
Connecting the Condensate Drain
Options
Anchoring the Machine
Connecting the Cooling Water
Fig.13 Condensate Drain Dimensions [MM]
Connecting the Extemal Heat Recovery System
Connecting External Control Air
Fig.14 Connecting the Cooling Water
Initial Start-Up Ensuring Safety
Instructions to be Observed before Commissioning or Re-Commissioning
Checking Installation and Operating Conditions
Tab. 45 Re-Commissioning after Storage
Setting the Overload Protection Cut-Out
Setting the Motor Overload Proteetion Switch
Filling Cooling Oil into the Airend
Tab. 46 Installation Conditions Checklist
Fig.15 Inlet Valve Filling Port
Fig.16 Coupling
Activaling and Deactivating the MODULA Tlng Control
Switching MODULATING Control to External Control Air
Fig.17 MODULA Tlng Contro!: Setting the Shut-Off Valve
Tab.47 MODULATING Control: Setting the Shut-Off Valve
Starting the Machine Tor the First Time
Setting the Set Point Pressure
Setting the Display Language
Operation
Switching on and off
Switching on
Switching off
Fig.18 Switching on and off
8.2 Switching off in an Emergency and Switching on Again
8.3 Switching on and off from a Remote Control Centre
Fig.19 Switching off in an Emergency
Switching on and off with the Clock
Fig.20 Switching on and off from a Remote Control Centre
Tab.48 Machine Identification
Tab. 49 Remote Control Identification
Interpreting Operation Messages
Acknowledging Alarm and Warning Messages
Fig.21 Switching on and off with the Clock
Tab.50 Machine Identification
Fig.22 Acknowledging Messages
Fault Recognition and Rectification
Basic Instructions
Other Faults
Tab. 51 Other Faults and Actions
Maintenance
Ensuring Safety
Following the Maintenance Plan
Logging Maintenance Work
Resetting Maintenance Interval Counters
Regular Maintenance Tasks
Cooling Oil: Change Interval
Tab. 52 Regular Maintenance Tasks
Regular Service Tasks
Control Cabinet: Clean or Renew the Filter Mat
Tab.53 Cooling Oil: Change Intervals
Cooler Maintenance
Fig.23 Switching Cabinet Ventilation
Water-Cooling Maintenance
Fig.24 Clean Cooler/Radiator
Cleaning or Renewing the Cooling Air Filter Mat
Fig.25 Cooling Air Filter Mat
Maintaining the Heat Recovery System
External Heat Recovery System
Changing the Air Filter
Motor Maintenance
Fig.26 Air Filter Maintenance
Fig.27 Drive Motor Maintenance
Checking the Coupling
Fig.28 Checking the Coupling
Testing the Pressure Relief Valve
Checking the Overheating Safety Shutdown Function
Checking the Cooling Oillevel
Venting the Machine (De-Pressurising)
Fig.29 Checking the Cooling Oil Level
Fig.30 Venting the Machine
10.15 Replenishing the Cooling Oil
Venling the Machine (De-Pressurising)
Fig.31 Replenishing the Cooling Oil
Topping up with Cooling Oil and Trial Run
Changing the Cooling Oil
Fig.32 Changing the Cooling Oil, Oil Separator Tank
Fig.33 Changing the Cooling Oil, Oil Cooler
Fig.34 Changing the Cooling Oil, Airend
Changing the Oil Filter
Changing the Oil Separator Cartridge
Fig.35 Changing the Oil Filter
Fig.36 Changing the Oil Separator Cartridge
Condensate Drainage Maintenance
Checking Condensate Drainage
Cleaning the Condensate Drain
Fig.37 Checking Condensate Drainage
Fig.38 Cleaning the Condensate Drain
Assembling Ssexible Pipe Connections
Fig.39 Assembling Flexible Pipe Connections
Documenting Maintenance and Service Work
11 Spares, Operating Materials, Service
Note the Nameplale
Ordering Consumable Parts and Operating Ssuids/Materials
Kaeser Air Service
Service Addresses
Spare Parts for Service and Repair
12 Decommissioning, Storage and Transport
Putting out of Operation
Packing
Storage
Transport
Safety
Transport with a Forklift Truck
Transport Wilh a Crane
Fig.40 Transport with a Forklift Truck
Disposal
Fig.41 Transport with a Crane
13 Annex
Pipeline and Instrument Flow Diagram (P+I Diagram)
Pipeline and Instrument Flow Diagram (P&I Diagram) MODULATING Control
Dimensional Drawing
Electrical Diagram
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Service Manual
Screw Compressor
FSD
SIGMA CONTROL 2
Manufacturer:
KAESER KOMPRESSOREN
96410 Coburg· PO Box 2143· GERMANY· Tel. +49-(0)9561-6400· Fax +49-(0)9561-640130
http://www.kaeser.com
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