Page 1 Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE Manufacturer: KAESER KOMPRESSOREN SE 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 www.kaeser.com...
Page 2 Original instructions /KKW/SCSGW 2.24 en Z1 SBA-SCHRAUBEN-DRY-W-SFC-SC /KKW/SSC 2.12 Z1 20210831 193213...
Page 3: Table Of Contents
Treating injuries from handling cooling oil ............3.10 Warranty ........................... 3.11 Environmental protection ....................Design and Function Enclosure ......................... Machine function ......................4.2.1 Water system functionality .................. 4.2.2 Frequency converter ................... Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 4 7.11.2 Cooling the machine with the secondary water system ........7.11.3 Cooling the machine with the secondary water system ........7.12 Hot air outlet with regulation ..................... Operation Switching on and off ......................8.1.1 Switching on ....................... Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 5 11.3 KAESER AIR SERVICE ....................121 11.4 Replacement parts for service and repair ................ 121 Decommissioning, Storage and Transport 12.1 Decommissioning ......................128 12.2 Packing ..........................12.3 Storage ..........................129 Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 6 12.5.1 Dispose of the machine in accordance with local environmental regulations ..132 12.5.2 Battery disposal in accordance with environmental guidelines ......Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) ............13.2 Dimensional drawing ......................141 13.3 Electrical Diagram ......................144 Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 7 Changing the oil filter ........................109 Fig. 51 Removing the filter element ......................110 Fig. 52 Installing the filter element ......................111 Fig. 53 Installing the filter bowl ....................... 112 Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 8 Fig. 59 Changing the control air filter ..................... Fig. 60 Transport with a forklift truck ...................... 130 Fig. 61 Transport with a crane ........................ 131 Fig. 62 Battery labelling .......................... 132 Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 9 Tab. 50 Condensate collecting line: Line cross-section ................Tab. 51 Recommissioning after storage ....................Tab. 52 Installation conditions checklist ....................Tab. 53 Machine identification ......................... Tab. 54 Remote control identification ...................... Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 10 Regular maintenance tasks ......................Tab. 59 Cooling oil: Change intervals ...................... Tab. 60 Regular service tasks ......................... Tab. 61 Logged maintenance tasks ......................Tab. 62 Spare parts ..........................120 Operator Manual Screw Compressor viii CSG-2 SFC W 902383 04 USE...
Page 11: Regarding This Document Using This Document
May result in a moderate physical injury tion Tab. 1 Danger levels and their definition (personal injury) Warning notices preceding a chapter apply to the entire chapter, including all sub-sections. Example: Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 12: Potential Damage Warnings
➤ 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. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 13 The cause is named in the help text ... ➤ ... as is a solution. This symbol identifies important information or measures regarding the protection of the envi‐ ronment. Further information Further subjects are introduced here. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 14: Technical Data Nameplate
Heat exchanger downstream of rotary dryer: — Finned-block cooler Heat exchanger downstream of rotary dryer: — Plate-type heat exchanger Pressure dew point measuring — Pressure dew point adjustment — Pressure dew point control — Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 15: Weight
Minimum cut-in tempera‐ ture [°F] Tab. 6 Temperature 1st stage airend - airend temperature CSG 70-2 – CSG 130-2 Typical airend discharge 285 – 420 temperature during oper‐ ation [°F] Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 16: Ambient Conditions
40 – 115 40 – 115 — perature [°F] * Higher altitudes are permissible only after consultation with the manufacturer. Tab. 9 Ambient conditions Ventilation The specified values are guidelines. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 17: Pressure
The illustration below shows the control range of the flow rate , dependant on all current pressure conditions at the compressed air outlet of the machine (local network pressure p100) Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 18: Rated Voltage 380V / 3 / 60Hz
Flow rate Q [cfm] at maximum working pressure 145 psig: p100 [psig] CSG 70-2 145 (pA Flow rate as per ISO 1217:2009. Annex E Tab. 13 Flow rate 380 V / 145 psig Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 19: Rated Voltage 460 V / 3 / 60 Hz
Flow rate Q [cfm] at maximum working pressure 145 psig: p100 [psig] CSG 70-2 3.49 3.49 145 (pA Flow rate as per ISO 1217:2009. Annex E Tab. 16 Flow rate 460 V / 145 psig Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 20: Cooling Oil Recommendation (Gear)
(ASTM D445) Viscosity at 8.2 mm /s (0.01 in 10.3 mm /s (0.02 in 100°C (212°F) (ASTM D445) (ASTM D445) Flash point 266°C (510°F) 280°C (536°F) (ASTM D92) (ASTM D92) Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 21: Cooling Oil Charge (Gearbox)
−39°C (-38.2°F) (ASTM D97) −39°C (-38.2°F) (ASTM D97) Tab. 20 Cooling oil recommendation (food processing) 2.10 Cooling oil charge (gearbox) CSG 70-2 – CSG 130-2 Total charge [gal] Tab. 21 Cooling oil charge Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 22: Motors And Power
Enclosure protection TEFC TEFC — Re-greasing interval [h]* — — — Grease requirement, — — — each anti-friction bear‐ ing [g] * Operating hours Tab. 23 Motor data, fan motor Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 23: Sound Emission
➤ Design the water systems so that total power consumption of the machine can be dissi‐ pated at all times. ➤ Comply with the instructions provided by the anti-freeze agent manufacturer. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 24 = water pressure displayed on SIGMA CONTROL 2, measured upstream of control valve V14 and downstream of the heat exchangers; see chapter 13.1, P&I diagram. higher values possible in individual cases Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 25: Tab. 25 Water System Requirements
Contact an authorized KAESER service representative if: ■ You wish to use an alternative heat transfer medium ■ You do not wish to evaluate the quality of the water yourself. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 26 When exposed to oxygen, ammonia corrodes copper, is highly volatile and can be detected more easily than ammonium. Technical specifications valid only for cooling water without glycol. CFU = colony-forming unit. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 27: Tab. 26 Water Quality
Tab. 27 Oil cooling heat exchanger specifications CSG 70-2 – CSG 130-2 Material: Tube bundle CuNi or stainless steel Material: Jacket (water Steel side) Material: Connection Stainless steel pieces (air side) Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 28: Heat Recovery
Individual design data My value Heating from [°F] Heating to [°F] Temperature difference (ΔT) [°F] Maximum available heat output [hp] (relative to ___ psig work‐ ing pressure) Flow rate [cfm] Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 29: Power Supply
Figure 2 and Figure 3. In a symmetrical three phase supply the phase an‐ gles and voltages are all the same. Other power supplies are not suitable. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 30: Power Supply Specifications
Current consumption [A] — CSG 120-2 CSG 130-2 — Pre-fuse [A] — Supply cable [AWG / 1x 4xAWG4/0 1x 4xMCM250 — MCM] Current consumption [A] — Tab. 33 Power supply details 380V/3/60Hz Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 31: Tab. 34 Power Supply Details 460V/3/60Hz
Current consumption [A] — CSG 120-2 CSG 130-2 — Pre-fuse [A] — Supply cable [AWG / 1x 4xAWG3/0 1x 4xAWG4/0 — MCM] Current consumption [A] — Tab. 34 Power supply details 460V/3/60Hz Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 32: Safety And Responsibility Basic Instructions
85 dB(A). User's responsibilities 3.4.1 Observe statutory and universally accepted regulations This is, for example, nationally applied European directives and/or valid national legislation, safety, and accident prevention regulations. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 33: Qualified Personnel
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'. Warning instructions are found before a potentially dangerous task. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 34: Safely Dealing With Sources Of Danger
Springs under tension or compression store energy. Uncontrolled release of this energy can cause serious injury or death. The safety relief valve and the inlet valve control cylinder are under powerful spring loading. ➤ Do not open or dismantle any valves. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 35 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. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 36: Safe Machine Operation
➤ Make sure the danger zone is clear of personnel. ➤ Do not step onto machine components to climb on the machine. Assembly ➤ Make sure no power is applied when electrical connections are made. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 37 ➤ Depressurize all pressurized components and enclosures. ➤ Allow the machine to cool down. ➤ Do not open the cabinet while the machine is switched on. ➤ Do not open or dismantle any valves. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 38: Organizational Measures
Operating personnel Maintenance Within the machine. Maintenance personnel Within a 3 ft. radius of the machine. Tab. 35 Danger areas Safety devices Various safety devices ensure safe working with the machine. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 39: Service Life Of Safety Functions
2. Have an authorized KAESER service representative check the reliability of the safety func‐ tions. Safety signs The tables list the various safety signs used and their meanings. The figures show the position of the safety signs on the machine inside and out. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 40: Fig. 4 Location Of Safety Signs Outside
Meaning Machine with option H23 Machine with option W5/W6 Loud machine noise! Serious ear damage can occur. ➤ Wear adequate ear protection. ➤ Never operate the unit without the enclosure. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 41 Wear protective clothing and gloves. Danger of falling or damage to the machine! ➤ Do not sit or walk on the enclosure. ➤ Do not place or store any load on the enclosure. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 42: Fig. 5 Location Of Safety Signs Front Side
Serious injury or death can result from loosening or opening component under pres‐ sure! ➤ Depressurize all pressurized components and enclosures. ➤ Ensure that that the machine remains depressurized. ➤ Check that machine is depressurized. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 43: Fig. 6 Location Of Safety Signs Rear Side
(lock out). ➤ Check that no voltage is present. Serious injury or death can result from tampering with this component! ➤ Never open (dismantle) valves. ➤ Contact authorized KAESER distributor. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 44: Fig. 7 Location Of Safety Signs With W5 Option
Touching electrically live components can cause serious injury or death. ➤ Isolate all conductors and lock out. ➤ Check that no voltage is present. Tab. 39 Safety signs with W5 option Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 45: Emergency Situations
Safety signs control cabinet Emergency situations 3.9.1 Correct fire fighting Calm and prudent action can save lives in the event of a fire. 1. Keep calm. 2. Give the alarm. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 46: Treating Injuries From Handling Cooling Oil
In addition, we accept no warranty obligation for: ■ the use of unsuitable parts or operating materials, ■ unauthorized modifications, ■ incorrect maintenance, ■ incorrect repair. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 47: Environmental Protection
➤ Observe relevant national regulations. This applies particularly to parts contaminated with compressor cooling oil. ➤ Do not allow cooling oil to escape to the environment or into the sewage system. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 48: Design And Function
The cooled compressed air is further compressed in the second stage airend and passes through a pulsation damper, check valve and second stage cooler into the air network. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 49 An oil pump delivers the cooling oil from the oil pan in the transmission box, and lubricates the bearings, the main gear, and the synchronization gears. If required, the cooling oil is cooled via a heat exchanger. Oil filters ensure the reliable function. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 50: Fig. 10 Machine Overview (View 1)
Condensate drain, first stage airend Check valve Condensate separator, first stage airend Inlet valve Drive motor Air filter Oil filler port Oil filter (cooling oil) Pulsation damper, first stage airend First stage airend Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 51: Water System Functionality
Option W5 or W6, both of which are primarily designed for the utilization of this accumulated heat energy, a second cooling circuit is also installed: the secondary water system. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 52 Option W5 when heat recovery is not utilized). 4.2.1.1 Primary water system Measuring points for temperatures and pressures in the compressed air path, primary water sys‐ tem, oil cooling. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 53: Fig. 12 Primary Water System (Schematic Diagram)
Air pressure at outlet p100 Air temperature at outlet T100 The cooling water is distributed to 4 parallel heat exchangers: ■ Air cooling after first compression stage Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 54 External disturbances will also lead to deviations in the regulating behavior. Small deviations are present on a continuous basis. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 55 Design and Function Machine function 4.2.1.2 Secondary water system (only with Options W5 or W6) Measuring points for temperatures and pressures in the compressed air path, water systems and oil cooling Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 56: Fig. 13 Primary And Secondary Water System (Schematic Diagram)
Cooling oil pressure prior to entering the ture at inlet bearing lubrication of both airends Primary water system: Inlet temperature Air temperature at outlet T100 (downstream of the heat exchanger) Air pressure at outlet p100 Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 57: Fig. 14 Options For The Primary And Secondary Water System (Schematic Diagram)
First stage airend Cooling water outlet: Primary water sys‐ Second stage airend Cooling water inlet: Primary water system Cooling water inlet: Secondary water sys‐ Cooling water outlet: Secondary water system Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 58: Frequency Converter
25.1 25.2 Tab. 43 Connection options for Option K10 4.2.2 Frequency converter The machine is equipped with a frequency converter that controls motor speed in proportion to the air demand. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 59: Floating Contacts
Triggers machine shutdown at excessively high temperatures. ■ Pressure transducer: Monitors the pressure conditions at various locations in the machine. ■ Enclosures and guards of moving parts and electrical connections: Protect against accidental contact. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 60: Operating Panel Sigma Control
Toggling the compressor between LOAD and IDLE is not possible. «Remote control» Switches the remote control on and off. «Timer control» Switches the time control on and off. Tab. 44 Keys Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 61: Fig. 16 Indicators - Overview
The LED lights when the machine is in remote control. Time control The LED lights when the machine is in timer control. Lights green when the machine switched on. Tab. 45 Indicators Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 62: Machine Operating Modes
More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐ ing manual. Machine operating modes ■ STOP The machine is connected to the power supply. The LED lights green. ON LED is extinguished. The machine is switched off. The Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 63: Frequency-Controlled Drive (Sfc)
Controller SIGMA CONTROL 2: Connection to control technology Connection to various control technology systems is possible. SIGMA CONTROL 2 Main Control System (MCS): ■ Slot for a communication module to connect to a control technology system. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 64: Machine Mountings
By regulating the bypass section by using control valve V32, the compressed air discharge temperature can be kept at a constant level. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 65: Auxiliary Heat Exchanger, Second Stage: Plate-Type Heat Exchanger
The condensate separator downstream of this plate-type heat exchanger replaces the unit usually installed downstream of the second stage heat exchanger in standard machines. See the P&I diagram in chapter 13.1 for the exact position of the plate-type heat exchanger. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 66: Heat Recovery
Only at the time, when the thermal energy no longer is completely and continuously removed, the secondary water system assumes the cooling function in order to ensure a constant re-entry tem‐ perature of the water within the primary water system. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 67 If the residual heat of the hot compressor components excessively heats the remaining cooling wa‐ ter in the compressor, the control valve slightly opens to admit some cooling water. Control valve V14 is then again fully closed. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 68 Option W6 Internal heat recovery system without internal water pump As option W5, but without internal water pump, expansion tank, connection for topping off, and au‐ tomatic bypass. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 69 The machine cannot be operated if the circulation of the primary water system is interrupted (due to maintenance or construction work or switching to Summer operation, for example) or if the pump fails. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 70: Installation And Operating Conditions
The exhaust air duct must be installed in such a way that exhaust air cannot re-enter the in‐ let. Precondition The floor must be level, firm and capable of bearing the weight of the machine. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 71: Ensuring Adequate Machine Room Ventilation
It conveys exhaust heat away from the machine, thus ensuring the necessary operating condi‐ tions. ➤ In the event that conditions for adequate ventilation of the machine room cannot be guar‐ anteed, please consult an authorized KAESER service representative for further advice. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 72: Inlet And Exhaust Air Ducting
➤ Please allow KAESER to advise on this subject. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 73: Installation
➤ Check all machine hose connectors with a hand-held pressure gauge to ensure that they all read 0 psig. Ensure that no oil will escape from the pressure gauge into the compressed air system during measurements. ➤ Do not open or dismantle any valves. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 74: Reporting Transport Damage
The compressed air system is vented completely to atmospheric pressure. Serious injury or death can result from loosening or opening components under pressure. ➤ Depressurize all pressurized components and enclosures. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 75: Connecting The Power Supply
6. Check that the tappings on the control voltage transformer are connected according to the power supply voltage. If not, change the tappings to suit the power supply voltage. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 76: Connecting The External Pressure Transducer
Connecting the water-cooling The cooling water is connected to the following water systems: ■ Secondary water system on machines with Option W5/W6 ■ Primary water system on machines without Option W5/W6 Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 77: Fig. 23 Connecting The Water-Cooling (Secondary Water System With Option W5/W6)
Fig. 24 Connecting the water-cooling (secondary water system with Option K10, without Option W5/W6) Cooling water inlet Connection port with sealing plug Cooling water outlet Safety relief valve Shut-off valve Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 78: Fig. 25 Connecting The Water-Cooling (Primary Water System)
Differential pressure-controlled pump ■ Suitable devices to balance changes in flow rate due to thermal strain, e.g. membrane pressure compensation tanks 2. Connect the cooling water lines to the fittings. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 79: Connecting A User-End Water Pump
Machine-internal temperature limits have priority over the set target value In READY mode, the machine valves close fully and open for a short period, if necessary. The control valve can be manually opened and closed, if necessary. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 80: Connecting The Heat Recovery To The Primary Water System
If required, contact KAESER for advice regarding suitable insulation measures. Floating contacts are provided for control of a pump installed at the user-end. ➤ Install and connect the heat exchanger in accordance with the guidelines from KAESER. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 81: Connecting The Internal Heat Recovery
Differential pressure-controlled pump. ■ Suitable devices to balance changes in flow rate due to thermal strain, e.g. membrane pressure compensation tanks 2. Connect the cooling water lines to the fittings. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 82: Connecting A User-End Water Pump Or Stop Valve
Condensate line Feature Value Max. length [ft] Max. delivery head [ft] <13 For longer lengths, please contact the manufacturer before installation. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 83: Tab. 48 Condensate Line
<350 350 – 700 701 – 1400 1 1/2 >1400 Compressed air flow rate as guide for the condensate volume to be expected Tab. 50 Condensate collecting line: Line cross-section Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 84: Options
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 13.2. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 85: Initial Start-Up Ensuring Safety
When working on the drive system Touching voltage carrying components can result in electric shocks, burns or death. Touching the fan wheel or the coupling while the machine is running can result in serious injury. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 86: Instructions To Be Observed Before Commissioning
➤ Are the power supply cable conductor cross-sections and fuse ratings 2.16 adequate? ➤ Have all electrical connections been checked for tightness? — ➤ Has the inspection been repeated after 50 operating hours following the initial commissioning? Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 87: Commissioning The Frequency Converter
(see motor nameplate). ➤ Check the motor overload protection switch setting. The overload protection switch shuts the machine down despite being correctly set? ➤ Contact an authorized KAESER SERVICE representative. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 88: Checking The Direction Of Rotation
You can set the language for texts on the display. This setting will be retained even when the ma‐ chine is switched off. 1. In operating mode, switch to the main menu with the «Enter» key. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 89: Setting The Set Point Pressure
This could affect the corrosion protection in the primary water system. ➤ Avoid intermediate settings. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 90: Fig. 31 Setting The Water System For Cooling Of The Airends
Setting the water system for cooling the cooling oil Switch-over valve Setting: Primary water system Setting: Secondary water system ➤ Set the lever of the switch-over valve according to the water system desired for cooling the cooling oil. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 91: Operating The Machine Without Heat Recovery System
The water is continuously circulated through the internal or the external water pump in the closed primary water system. Precondition The primary water system is filled and is under sufficient pressure. The control valve V10 is sufficiently opened when the machine is running. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 92: Cooling The Machine With The Secondary Water System
Because the discharge temperature depends on various operating parameters, it may be higher than the set target value. Further information See the SIGMA CONTROL 2 user manual for the various operating modes for the valve V32. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 93: Operation
It can restart automatically as soon as power is restored. Result The compressor motor starts as soon as system pressure is lower than the set-point pressure (cut- off pressure). Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 94: Switching Off
Switching off ➤ Press the EMERGENCY STOP push-button. The EMERGENCY STOP button remains latched after actuation. The compressor's pressure system is vented and the machine is prevented from automatically restarting. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 95: Switching On And Off From A Remote Control Center
3. Press the «Remote control» key. Remote control LED lights. The machine can be remotely controlled. Switching on and off with the shift clock Precondition The shift clock is programmed. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 96: Interpreting Operation Messages
■ Message coming LED flashes ■ Message acknowledged: LED illuminates ■ Message going: LED off ■ Message coming LED flashes ■ Message going: LED flashes ■ Message acknowledged: LED off Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 97: Fig. 37 Acknowledging Messages
➤ Acknowledge the message with the «Acknowledge» key. Warning LED extinguishes. Further information A list of possible alarm messages occurring during operation can be found in the service manual SIGMA CONTROL 2. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 98: Fault Recognition And Rectification
Vacuum intake nozzle clogged. Clean the vacuum intake noz‐ zle. Fine filter clogged. Replace the filter element. Main pressure p5 too low dur‐ Contact an authorized KAESER ing operation. service representative. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 99: Tab. 56 Other Faults And Remedies
Other faults Fault Possible cause Remedy Cooling oil in the exhaust duct‐ Solenoid valve defective. Contact an authorized KAESER ing. service representative. Ultra-fine filter defective. Tab. 56 Other faults and remedies Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 100: 10 Maintenance
The following safety instructions relate to any work on components that could be under pressure. ➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐ sure that no compressed air can flow back into the machine. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 101: Maintenance Schedule
Starting from a predefined starting value, maintenance counters count down the operating hours between two maintenance tasks. Reset the counter to the original value once the task has been carried out. Precondition Maintenance carried out, warning message acknowledged password level 2 activated. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 102: Regular Maintenance Tasks
At least every 4 years Up to 12000 h Gear ventilation: 10.16 Change the filter element. At least every 4 years Change the control air filter. 10.19 h = operating hours Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 103: Cooling Oil: Change Interval
At least every 2 years Up to 12000 h Service the following valves: At least every 4 years ■ Check valve at pulsation dampener ■ Overflow valve h = operating hours Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 104: Checking The Machine For Leaks
0113 is displayed on the SIGMA CONTROL 2, change the prefilter at If the warning message the earliest opportunity (see chapter 10.4.1). Change the filter mat at the same time, see chapter 10.6. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 105: Replacing The Prefilter
Do not clean the air filter. A damaged air filter can permit dirt to enter the pressure system and cause damage to the machine. Material Air filter (incl. prefilter) Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 106: Control Cabinet: Clean Or Replace The Filter Mats
Spare parts (as required) Precondition The power supply disconnecting device is switched off, the device is locked off, the absence of voltage has been verified. The machine is cooled down. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 107: Fig. 40 Switching Cabinet Ventilation
3. Replace the filter mat if cleaning is not possible or if the change interval has expired. 4. Reinsert the filter mat in the frame and latch in the ventilation grill. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 108: Machine Ventilation: Clean Or Replace The Filter Mats
1. Remove and dispose of the filter mat 2. Carefully insert the new filter mat in the retaining frame. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 109: Cleaning The Heat Exchanger
➤ The required grease quantity is shown in the tables in chapter 2.11. Material Bearing grease: UNIREX N3 Cleaning cloth Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 110: Checking The Coupling
➤ Have the fan motor checked by a KAESER service representative during the course of a main‐ tenance call. 10.9 Checking the coupling A defective coupling is recognizable by: ■ noisy running ■ surface cracks ■ color change. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 111: Fig. 43 Checking The Coupling
4. Close all access doors and replace all enclosure panels. Does the coupling have cracks or changes in color? ➤ Have a damaged coupling changed by an authorized KAESER service representative. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 112: Checking The Overheating Safety Shutdown Function
Testing the safety relief valves Never operate the machine without a correctly functioning safety relief valve. The safety relief valves for both airends can be externally tested at a suitable test stand. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 113: Checking Cooling Oil Level And Replenishing Cooling Oil (Gear)
If possible, check the cooling oil level when the machine is in Idle mode! High noise level when doors are open! Risk of hearing damage. ➤ Always wear ear protection. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 114: Fig. 45 Checking The Cooling Oil Level
The sticker on the oil separator tank specifies the type of oil used. Precondition The power supply disconnecting device is switched off, lock out and tag out the device, verify the absence of voltage. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 115: Changing The Cooling Oil (Gear)
You can drain the cooling oil faster when it is warm (T66 >130 °F) and thus less viscous. The power supply disconnecting device is switched off, lock out and tag out the device, verify the absence of voltage Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 116: Fig. 47 Draining Cooling Oil From The Transmission Pan
1. Place cooling oil receptacle below the drainage opening 2. Slowly open the shut-off valve and completely drain the cooling oil. ➤ Dispose of used oil in accordance with applicable environmental provisions. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 117: Fig. 48 Draining The Cooling Oil From The Heat Exchanger For Oil Cooling
3. Close the shut-off valves and remove the plug-in nozzle from the hose coupling. ➤ Dispose of used oil in accordance with applicable environmental provisions. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 118: Changing The Oil Filter
Changing the oil filter Material Spare part Cooling oil receptacle Precondition The power supply disconnecting device is switched off, lock out and tag out the device, verify the absence of voltage Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 119: Compressed Air Filter: Changing The Filter Element For Gear Ventilation
Compressed air filter: Changing the filter element for gear ventila‐ tion ➤ Carefully handle and manually install all components in order to avoid damages. This ap‐ plies to sealing surfaces, in particular. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 120: Removing The Filter Element
The filter bowl is clearly corroded? ➤ Determine the cause (e.g., composition of the compressed air, operating conditions). ➤ Replace the compressed air filter completely. Dispose of the contaminated filter element according to environmental regulations. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 121: Installing The Filter Element
3. Use one turn to screw the filter element into the filter bowl. 4. Fully grease the O-ring and insert between filter element and filter bowl. 5. Grease the O-ring Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 122: Installing The Filter Bowl
6. Note the year for the next maintenance on the maintenance sticker. (See maintenance intervals in chapter 10.2.3). max points to the month for 7. Attach the maintenance sticker in such a manner that the marking the next maintenance. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 123: Venting The Machine (Depressurizing)
If no shut-off valve is provided by the user, the complete air network must be vented. ➤ Close the user's shut-off valve between the machine and the air distribution network. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 124: Condensate Drain Maintenance
3. With one hand, lightly touch the condensate line on the condensate drain. 4. With your other hand, push and hold the «TEST» key on the condensate drain for at least 2 seconds. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 125: Checking The Condensate Drain Downstream From Stage 2
If required: O-ring 16x2 (5.1519.0) Precondition The power supply disconnecting device is switched off, lock out and tag out the device, the absence of voltage has been verified. The machine is fully vented. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 126: Fig. 58 Replacing The Service Unit
To ensure that the condensate drain functions correctly, use only KAESER service units. Precondition Make sure that the top of the service unit and the contact springs are clean and dry. 1. Fit the insulation (if installed) to the service unit Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 127: Changing The Control Air Filter
The machine is fully vented. Danger of burns from hot components. ➤ Wear long-sleeved clothing and protective gloves. Fig. 59 Changing the control air filter Filter bowl Filter element bracket Filter element Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 128 2. Unscrew the filter element bracket counterclockwise and remove the old filter element 3. Place the new filter element on the filter element bracket and tighten the screws. 4. Screw in the filter bowl. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 129: Documenting Maintenance And Service Work
Documenting maintenance and service work Equipment number: ➤ Enter maintenance and service work carried out in the checklist below. Date Maintenance task carried out Operating hours Signature Tab. 61 Logged maintenance tasks Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 130: 11 Spares, Operating Materials, Service
Filter mat (control cabinet frequency converter) 1150 Filter mat (intake air) 1053 Oil filter (gear) 1200 Service Unit condensate drain 9602 Cooling oil 1610 Bearing grease [g] 9.0915.0 6.3234.0 Tab. 62 Spare parts Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 131: Kaeser Air Service
Use these parts lists to plan your material requirement according to operating conditions and to or‐ der the required spare parts. ➤ Make sure that any service or repair tasks not described in this manual are carried out by an authorized KAESER service representative. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 132 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 133 Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering. Before and during all work, be sure to read and follow the safety and service instructions in the machine's service manual! Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 134 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 135 Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering. Before and during all work, be sure to read and follow the safety and service instructions in the machine's service manual! Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 136 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 137 Please quote the part number and serial number of the machine together with the item number and the description of the part when ordering. Before and during all work, be sure to read and follow the safety and service instructions in the machine's service manual! Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 138: 12 Decommissioning, Storage And Transport
The on-site shut-off valve is closed in order to prevent back-flow of compressed air into the com‐ pressor. 1. Switch control valves V10 (if applicable), V12 and V14 to operating mode "Open". 2. Switch off and lock out the power supply disconnecting device. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 139: Packing
Moisture and frost can damage the machine! ➤ Prevent ingress of moisture and formation of condensation. ➤ Maintain a storage temperature of >32 °F. ➤ Store the machine in a dry, frost-proof room. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 140: Transporting
➤ Consult KAESER if you require suitable load-carrying and attachment devices or have questions regarding the correct use. Precondition Load-carrying and attachment devices meet the local safety regulations. The crane, load-carrying and attachment devices or the lifted machine do not endanger personnel. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 141: Fig. 61 Transport With A Crane
3. Carry out a lifting test: Slightly lift the machine to check whether machine remains in horizontal position and does not teeter. 4. Transport the machine only after a successful lifting test. Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 142: Disposal
You actively contribute to the protection of our environment when you take used batteries to the appropriate recycling system. Further information Refer to the SIGMA CONTROL 2 User Manual for details regarding battery removal. Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 143: 13 Annex
Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 144 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 145 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 146 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 147 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 148 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 149 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 150 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 151: Dimensional Drawing
Annex 13.2 Dimensional drawing 13.2 Dimensional drawing Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 152 Annex 13.2 Dimensional drawing Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 153 Annex 13.2 Dimensional drawing Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 154: Electrical Diagram
Annex 13.3 Electrical Diagram 13.3 Electrical Diagram Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 155 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
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Page 159 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 160: Electrical Diagram
3-pole Class CC power wiring -W280 -W280 3x1x2/0 AWG 3x1x2/0 AWG 600 V, 90°C, black 600 V, 90°C, black motor cable -W19 -W19 9YSLCY-JB 9YSLCY-JB 4G95 mm² 4G95 mm² Tape-wound core 7.8538.00020 7.8538.00020 Magnetec Magnetec M113 M113 Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 161 -W280 -W280 3x2x2/0 AWG 3x2x2/0 AWG 600 V, 90°C, black 600 V, 90°C, black motor cable -W19 -W19 9YSLCY-JB 9YSLCY-JB 2x 4G50 mm² 2x 4G50 mm² Tape-wound core 7.8538.00010 7.8538.00010 Magnetec Magnetec M116 M116 Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 162 -W280 -W280 3x2x2/0 AWG 3x2x2/0 AWG 600 V, 90°C, black 600 V, 90°C, black motor cable -W19 -W19 9YSLCY-JB 9YSLCY-JB 2x 4G70 mm² 2x 4G70 mm² Tape-wound core 7.8538.00010 7.8538.00010 Magnetec Magnetec M116 M116 Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 163: Common Parts
EMERGENCY STOP pushbutton -S1 7.3217.0 QRUV bracket + auxiliary contact 7.3218.0 MTHOO auxiliary contact 7.3219.0 Schlegel Schlegel outlet filter 7.2752.00050 Rübsamen&Herr Rübsamen&Herr GV700 control cabinet KAESER KAESER 227732.0 control panel KAESER KAESER 230457.0 Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 164 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 165 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
Page 166 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
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Page 168 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...
Page 169 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor 902383 04 USE CSG-2 SFC W...
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Page 190 Annex 13.3 Electrical Diagram Operator Manual Screw Compressor CSG-2 SFC W 902383 04 USE...

KAESER KOMPRESSOREN CSG-2 SFC W Operator's Manual

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