Related Manuals for KAESER Aircenter SX 7.5
Summarization of Contents
Regarding this Document
1.1 Using the Document
Instructions on how to use the service manual and its role in machine operation.
1.2 Additional Documents
Lists additional documents provided with the service manual for machine operation.
1.3 Copyright
Copyright information for the service manual, queries regarding use should be referred to KAESER.
1.4 Symbols and Identification
Explains symbols and identification elements used throughout the manual for clarity.
1.4.1 Warnings
Explains the different levels of danger warnings (DANGER, WARNING, CAUTION) used in the manual.
1.4.2 Other instructions and symbols
Explains other symbols and conventions used in the manual for important information.
Technical Data
2.1 Nameplate
Details about the machine's nameplate and the technical information it contains.
2.2 Options
Lists available options for the machine with their corresponding option codes.
2.3 Weight
Provides the weight specifications for the SX 3 and SX 7.5 machine models.
2.4 Temperature
Specifies operating and shutdown temperatures for the airend and machine.
2.5 Ambient Conditions
Details permissible ambient conditions like elevation, temperature, and humidity.
2.6 Ventilation
Provides minimum guide values for ventilation, including inlet aperture and fan flow rate.
2.7 Pressure
Specifies the safety relief valve activating pressure in psig.
2.8 Air receiver
Details the volume capacity of the air receiver for the SX 3 and SX 7.5 models.
2.9 Free air delivery
Lists free air delivery (FAD) at different altitudes and pressures for both models.
2.10 Sound pressure level
Provides sound pressure level measurements under specified operational conditions.
2.11 Motors and power
Details motor specifications, including rated power, speed, and enclosure protection.
2.12 Cooling Oil Recommendation
Recommends cooling oils and provides basic information on their properties and selection.
2.13 Cooling oil Volume
Specifies the cooling oil capacity and topping-up volume for the machine.
2.14 Power Supply
Outlines the basic requirements for the machine's electrical power supply.
2.15 Power supply specifications
Provides detailed specifications for power supply connections, including wire sizes and fuses.
2.16 Refrigeration dryer
Lists model details and specifications for the refrigeration dryer component.
Safety and Responsibility
3.1 Basic Information
General information about safety and regulatory compliance for machine operation.
3.2 Specified Use
Defines the intended industrial use of the machine and manufacturer's liability.
3.3 Improper Use
Lists actions that constitute improper use of the compressor and potential consequences.
3.4 User's Responsibilities
Outlines user responsibilities regarding regulations, personnel, and maintenance.
3.4.1 Observe statutory and universally accepted regulations
Emphasizes adherence to legal and safety regulations during installation and operation.
3.4.2 Qualified personnel
Defines qualifications required for authorized operators and maintenance personnel.
3.4.3 Adherence to inspection schedules and accident prevention regulations
Stresses following inspection schedules and accident prevention rules.
3.5 Dangers
Introduces general dangers that can arise during machine operation.
3.5.1 Safely Dealing with Sources of Danger
Details how to safely handle dangers related to electricity, pressure, and rotating components.
3.5.2 Safe Machine Operation
Provides guidance on safe practices for transport, installation, and operation.
3.5.3 Organizational Measures
Outlines organizational measures for safety, like designating personnel and reporting faults.
3.5.4 Danger Areas
Identifies specific areas around the machine that are dangerous to personnel.
3.6 Safety Devices
Lists and describes the machine's integrated safety devices and their functions.
3.7 Safety Signs
Shows the location and meaning of safety signs displayed on the machine.
3.8 In Emergency
Provides instructions for emergency situations like fire fighting and handling injuries.
3.9 Warranty
States the warranty conditions, exclusions, and requirements for service.
3.10 Environmental Protection
Provides guidelines for environmental protection, disposal, and handling of materials.
Design and Function
4.1 Housing
Describes the machine's enclosure and its various functions like insulation and cooling.
4.2 Function
Explains the operational principles and key components of the compressor machine.
4.3 Refrigeration Dryer
Details the function of the refrigeration dryer in removing moisture from compressed air.
4.4 Air receiver
Describes the air receiver's function in storing compressed air and filtering consumption peaks.
4.5 Floating relay contacts
Explains the purpose and connection of floating relay contacts for signal transfer.
4.6 Options
Lists and describes available machine options, such as mountings and control systems.
4.6.1 Option H1 Machine mountings
Describes the machine mountings used for anchoring the unit securely to the floor.
4.6.2 Option C16 LOAD-IDLE control by remote contact
Explains the connection and function of remote control for LOAD-IDLE operation.
4.6.3 Option F1 Microfilter
Describes the function of the microfilter in removing aerosols and solid particles.
4.6.4 Option F2 Activated carbon filter
Describes the function of the activated carbon filter in removing vapors.
4.7 Operating modes and control modes
Details the different operating and control modes of the compressor machine.
4.8 Refrigeration Dryer Control Modes
Explains the CONTINUOUS and TIMER control modes for the refrigeration dryer.
4.9 Safety Devices
Lists and describes the machine's integrated safety devices and their functions.
4.10 SIGMA CONTROL BASIC Keys and Indicators
Identifies the keys and indicators on the SIGMA CONTROL BASIC controller interface.
4.11 SIGMA CONTROL BASIC function
Details the functions, display layout, parameters, and messages of the controller.
Installation and Operating Conditions
5.1 Safety
General safety instructions and precautions for machine installation and operation.
5.2 Installation conditions
Details requirements for machine installation location, clearances, and environmental factors.
5.2.1 Determining location and clearances
Specifies necessary distances from walls and ventilation requirements for installation.
5.2.2 Ensure adequate ventilation
Emphasizes the importance of proper ventilation for machine cooling and performance.
5.2.3 Exhaust duct design
Provides guidance on designing exhaust ducts for efficient cooling air flow.
5.3 Using the Compressor to Supply A Compressed Air System.
Instructions for connecting the compressor to a compressed air system and system pressure limits.
Installation
6.1 Safety
Safety instructions specific to the installation process of the machine.
6.2 Reporting Transport Damage
Procedures for reporting any damage incurred by the machine during transport.
6.3 Making the Compressed Air Connection
Steps for connecting the machine to the compressed air system.
6.4 Making the Power Supply Connection
Instructions for safely connecting the machine to the electrical power supply.
6.4.1 Option T2 Refrigeration dryer: Connecting the transformer according to the power supply.
Details transformer connection for the refrigeration dryer based on power supply voltage.
6.5 Connecting the condensate drain
Instructions for connecting the condensate drain hose to the machine.
6.6 Options
Details additional installation options and their procedures.
6.6.1 Option H1 Anchoring the machine
Instructions for anchoring the machine securely to the floor using appropriate fixings.
6.6.2 Option C16 Connecting the remote contact LOAD-IDLE control
Guides the connection of remote control for LOAD-IDLE operation via floating relay contact.
Initial Start-up
7.1 Safety
Safety precautions to be followed during the initial machine commissioning process.
7.2 To be noted before commissioning
Important points and checks to consider before starting the commissioning process.
7.3 Checking positioning and operating conditions
Checklist for verifying correct setup and operating conditions before initial startup.
7.4 Setting the overload protection cut-out
Instructions for setting the motor overload protection cut-out based on motor current.
7.5 Hot gas bypass valve setting
Details the adjustment of the hot gas bypass valve for altitude compensation.
7.6 Pouring cooling oil into the airend
Step-by-step guide for filling the airend with the correct quantity of cooling oil.
7.7 Checking direction of rotation
Instructions for verifying the correct direction of motor and airend rotation.
7.8 Starting the machine for the first time
Procedure for the initial startup of the machine and its first operation.
7.9 Checking the Door Interlock Switch
Verifies the function of the door interlock safety switch on the machine.
7.10 Setting the setpoint pressure
Instructions for adjusting the machine's setpoint pressure for optimal operation.
Operation
8.1 Switching on and off
Steps for safely switching the machine on and off using the control panel.
8.2 Switching Off in an Emergency and Switching On again
Procedures for emergency shutdown using the STOP button and subsequent restart.
8.3 Acknowledging alarm and warning messages
How to acknowledge and respond to alarm and warning messages on the controller.
8.4 Setting parameters
Instructions for accessing and modifying machine parameters via the controller.
Fault Recognition and Rectification
9.1 Basic Information
Introduces fault types (alarm, warning, other) and general troubleshooting guidelines.
9.2 Alarm messages (machine stop)
Lists alarm codes, their meanings, and recommended actions for machine stop faults.
9.3 Warning messages
Lists warning codes, their meanings, and recommended actions for warning messages.
9.4 Other Faults
Addresses faults not covered by alarms or warnings, with possible causes and remedies.
Maintenance
10.1 Safety
Safety instructions and precautions specific to performing maintenance procedures.
10.2 Maintenance Schedule
Outlines the recommended maintenance schedule and tasks for the machine.
10.2.1 Logging maintenance work
Guidance on recording performed maintenance tasks and deviations from recommendations.
10.2.2 Resetting maintenance interval counters
Instructions for resetting maintenance interval counters after tasks are completed.
10.2.3 Regular maintenance tasks
Lists routine maintenance tasks with their intervals and references to relevant chapters.
10.2.4 Cooling oil changing interval
Details intervals for changing cooling oil based on lubricant type and operating conditions.
10.2.5 Regular service work
Lists necessary service tasks that should be performed by authorized representatives.
10.3 Cooler: Cleaning or Renewing the Filter Mats
Instructions for cleaning or replacing filter mats for the cooler to ensure adequate cooling.
10.4 Cleaning or Replacing the Control Cabinet Filter Mats
Instructions for cleaning or replacing filter mats in the control cabinet for protection against dirt.
10.5 Cooler Maintenance
Emphasizes regular cleaning of the cooler for reliable machine and air cooling.
10.6 Air Filter Maintenance
Instructions for maintaining the air filter element to prevent dirt ingress.
10.7 Drive Motor Maintenance
Information on drive motor bearing maintenance, noting they are permanently greased.
10.8 Maintaining the drive belts
Instructions for visually checking drive belts for damage and changing them if necessary.
10.9 Pressure relief valve checking
Procedure for checking the pressure relief valve's activating pressure.
10.10 Checking the Overheating Safety Shutdown Function
How to check the safety shutdown function for overheating of the airend discharge temperature.
10.11 Checking the cooling oil level
Guide to checking and topping up the cooling oil level via the viewing window.
10.12 Venting the machine (depressurizing)
Steps for safely venting pressure from the machine before maintenance.
10.13 Topping up the Cooling Oil
Instructions for adding cooling oil to the machine after ensuring it is vented.
10.13.1 Venting the Machine (depressurizing)
Steps for safely venting pressure from the machine before topping up cooling oil.
10.13.2 Top up with cooling oil and test run
Guide for topping up cooling oil and performing a test run to check for leaks.
10.14 Changing the cooling oil
Detailed steps for draining and changing the cooling oil, including filter and cartridge replacement.
10.15 Changing the oil filter
Instructions for changing the oil filter, including preparation and post-change checks.
10.16 Changing the oil separator cartridge
Instructions for changing the oil separator cartridge, noting factors influencing its life.
10.17 Refrigeration dryer maintenance
General information on refrigeration dryer maintenance, noting sealed circuits and certified personnel.
10.17.1 Cleaning the refrigerant condenser
Steps for cleaning the refrigerant condenser using compressed air.
10.17.2 Checking condensate drainage
How to check the condensate drain function and troubleshoot blockages.
10.17.3 Condensate drain maintenance
Instructions for maintenance of the condensate drain unit, including replacement if needed.
10.18 Service air receiver
Maintenance tasks related to the service air receiver, including condensate drainage.
10.18.1 Drain condensate manually.
Procedure for manually draining condensate from the air receiver tap.
10.18.2 Checking the safety relief valve
Procedure for testing the air receiver's safety relief valve.
10.19 Document maintenance and service work.
Provides a log for documenting performed maintenance and service activities.
Spares, Operating Materials, Service
11.1 Note the nameplate
Explains the importance of the nameplate for identifying the machine and ordering spares.
11.2 Ordering consumable parts and operating fluids/materials
Guide to ordering genuine KAESER consumable parts and operating fluids/materials.
11.3 KAESER AIR SERVICE
Details the services offered by KAESER AIR SERVICE for enhanced reliability and savings.
11.4 Service Addresses
Mentions that addresses of KAESER representatives are provided at the end of the manual.
11.5 Spare Parts for Service and Repair
Guidance on planning material requirements and ordering spare parts for service and repair.
Decommissioning, Storage and Transport
12.1 Putting Out of Operation
Procedures for taking the machine out of operation temporarily or for a longer period.
12.2 Packing
Instructions for packing the machine for transport to protect it from mechanical damage.
12.3 Storage
Guidance on storing the machine to prevent corrosion and damage from moisture.
12.4 Transporting
General safety guidelines and considerations for transporting the machine.
12.4.1 Safety
Safety considerations for transporting the machine, including weight and center of gravity.
12.4.2 Transporting with a forklift
Specific instructions for safely transporting the machine using a forklift.
12.4.3 Transporting with a crane
Guidelines for safely transporting the machine using a crane and lifting cradle.
12.5 Disposal
Instructions for properly disposing of the machine and its components according to regulations.
Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)
Refers to the pipeline and instrument flow diagrams for the machine's systems.
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode
Provides the P+I diagram specifically for the MODULATING control mode.
13.3 Dimensional drawing
Refers to dimensional drawings that provide physical measurements of the machine.
13.4 Electrical Diagram
Refers to the electrical diagrams illustrating the machine's wiring and components.
13.5 Service Manual for Compressed Air Filter
Refers to a separate service manual for specific information on compressed air filters.
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