KAESER KOMPRESSOREN FSD SIGMA CONTROL 2 Manuals

Manuals and User Guides for KAESER KOMPRESSOREN FSD SIGMA CONTROL 2. We have 1 KAESER KOMPRESSOREN FSD SIGMA CONTROL 2 manual available for free PDF download: Service Manual

KAESER KOMPRESSOREN FSD SIGMA CONTROL 2 Service Manual (142 pages)

Screw Compressor

Brand: KAESER KOMPRESSOREN | Category: Air Compressor | Size: 5 MB

Table of Contents
3
Using this Document
11
Further Documents
11
Copyright
11
Symbols and Labels
11
Warnings
11
Tab. 1 Danger Levels and Their Definition (Personal Injury)
11
Potential Damage Warnings
12
Other Alerts and Their Symbols
12
Tab. 2 Danger Levels and Their Definition (Damage to Property)
12
Technical Specifications Nameplate
14
Optional Accessories
14
Weight
14
Tab. 3 Nameplate
14
Tab.4 Optional Accessories
14
Select Temperature
15
Ambient Conditions
15
Tab. 5 Machine Weight
15
Tab. 6 Select T Emperature
15
Tab. 7 Ambient Conditions
15
Ventilation
16
Fig.1 Maximum Relative Humidity of Intake Air
16
Tab. 8 Overview Ventilation (50 Hz)
16
Pressure
17
Delivery
17
Tab. 9 Overview Ventilation (60 Hz)
17
Tab. 10 Pressure Relief Valve Activating Pressure (50Hz)
17
Tab. 11 Pressure Relief Valve Activating Pressure (60Hz)
17
Cooling Oil Recommendation
18
Tab. 12 FAD (50 Hz)
18
Tab. 13 FAD (60 Hz)
18
Tab.14 Cooling Oil Recommendation
19
Tab. 15 Cooling Oil Recommendation (Food Processing)
19
Cooling Oil Charge
20
Motors and Power
21
Compressor Drive Motor
21
Fan Motor
21
Tab. 20 Compressor Drive Motor
21
Tab. 21 Compressor Motor (60Hz)
21
Fan Motor
22
Tab. 22 Fan Motor (Option K1)
22
Tab. 23 Fan Motor (Option K1. 60Hz)
22
Tab. 24 Fan Motor (Option K2. 50Hz)
22
Tab. 25 Fan Motor (Option K2. 60Hz)
22
Noise Emission
23
Powersupply
23
Power Supply Specifications
23
Tab. 26 Noise Emission
23
Tab. 27 Noise Emission
23
Mains Frequency: 50 Hz
24
Mains Frequency: 60 Hz
24
Water Cooling
25
Design Data
25
Cooling Water Quality
26
Available Heat Capacity
27
Tab. 35 Cooling Water Quality
27
Tab. 36 Heat Capacity (Option W1)
27
Safety and Responsibility
28
Basic Instructions
28
Specified Use
28
Improper Use
28
User's Responsibilities
28
Observe Statutory and Universally Accepted Regulations
28
Determining Personnel
29
Adherence to Inspection Schedules and Accident Prevention Regulations
29
Dangers
30
Safely Dealing with Sources of Danger
30
Tab.37 Inspection Intervals According to Ordinance on Industrial Safety and Health
30
Safe Machine Operation
32
Organisational Measures
34
Danger Areas
34
Safety Devices
35
Safety Signs
35
Fig.2 Location of Safety Signs
35
Emergency Situations
36
Correct Fire Fighting
36
Tab. 39 Safety Signs
36
Treating Injuries from Handling Cooling Oil
37
Warranty
37
Environment Protection
38
Design and Function Enclosure
39
Machine Function
39
Fig.3 Enclosure Overview
39
Floating Relay Contacts
40
Fig.4 Machine Layout
40
Options
41
Machine Mountings
41
Water-Cooling
41
Cooling Air Filter Mat
41
Fig.5 Machine Mountings
41
Fig.6 Water-Cooling (Option K2)
41
Prepared Tor Extemal He at Recovery
42
Control Air Connection Tor Modulating Control
42
Fig.7 Cooling Air Filter Mat (Option K3)
42
Operating Modes and Control Modes
43
Operating Modes
43
Control Modes
43
Safety Devices
45
Operating Panel SIGMA CONTROL 2
45
Fig.8 Keys
45
Fig.9 Indicators
46
Tab.42 Buttons
46
Fig.10 RFID Sensor Field
47
Tab. 43 Displays
47
Installation and Operating Conditions
49
Ensuring Safety
49
Installation Conditions
49
Determining Loeation and Clearances
49
Ensuring the Machine Room Ventilation
50
Fig.11 Recommended Machine Placement and Dimensions [MM]
50
Exhaust Duct Design
51
Operating the Machine in a Compressed Air Network
51
Installation
52
Ensuring Safety
52
Reporting Transport Damage
53
Connecting the Machine with the Compressed Air Network
53
Connecting the Power Supply
53
Fig.12 Compressed Air Pipework
53
Connecting the Condensate Drain
54
Options
55
Anchoring the Machine
55
Connecting the Cooling Water
55
Fig.13 Condensate Drain Dimensions [MM]
55
Connecting the Extemal Heat Recovery System
56
Connecting External Control Air
56
Fig.14 Connecting the Cooling Water
56
Initial Start-Up Ensuring Safety
58
Instructions to be Observed before Commissioning or Re-Commissioning
59
Checking Installation and Operating Conditions
59
Tab. 45 Re-Commissioning after Storage
59
Setting the Overload Protection Cut-Out
60
Setting the Motor Overload Proteetion Switch
60
Filling Cooling Oil into the Airend
60
Tab. 46 Installation Conditions Checklist
60
Fig.15 Inlet Valve Filling Port
61
Fig.16 Coupling
61
Activaling and Deactivating the MODULA Tlng Control
62
Switching MODULATING Control to External Control Air
62
Fig.17 MODULA Tlng Contro!: Setting the Shut-Off Valve
62
Tab.47 MODULATING Control: Setting the Shut-Off Valve
62
Starting the Machine Tor the First Time
63
Setting the Set Point Pressure
63
Setting the Display Language
63
Operation
65
Switching on and off
65
Switching on
65
Switching off
65
Fig.18 Switching on and off
65
8.2 Switching off in an Emergency and Switching on Again
66
8.3 Switching on and off from a Remote Control Centre
66
Fig.19 Switching off in an Emergency
66
Switching on and off with the Clock
67
Fig.20 Switching on and off from a Remote Control Centre
67
Tab.48 Machine Identification
67
Tab. 49 Remote Control Identification
67
Interpreting Operation Messages
68
Acknowledging Alarm and Warning Messages
68
Fig.21 Switching on and off with the Clock
68
Tab.50 Machine Identification
68
Fig.22 Acknowledging Messages
69
Fault Recognition and Rectification
71
Basic Instructions
71
Other Faults
71
Tab. 51 Other Faults and Actions
72
Maintenance
73
Ensuring Safety
73
Following the Maintenance Plan
74
Logging Maintenance Work
74
Resetting Maintenance Interval Counters
74
Regular Maintenance Tasks
74
Cooling Oil: Change Interval
75
Tab. 52 Regular Maintenance Tasks
75
Regular Service Tasks
76
Control Cabinet: Clean or Renew the Filter Mat
76
Tab.53 Cooling Oil: Change Intervals
76
Cooler Maintenance
77
Fig.23 Switching Cabinet Ventilation
77
Water-Cooling Maintenance
78
Fig.24 Clean Cooler/Radiator
78
Cleaning or Renewing the Cooling Air Filter Mat
79
Fig.25 Cooling Air Filter Mat
79
Maintaining the Heat Recovery System
80
External Heat Recovery System
80
Changing the Air Filter
80
Motor Maintenance
81
Fig.26 Air Filter Maintenance
81
Fig.27 Drive Motor Maintenance
82
Checking the Coupling
83
Fig.28 Checking the Coupling
83
Testing the Pressure Relief Valve
84
Checking the Overheating Safety Shutdown Function
84
Checking the Cooling Oillevel
85
Venting the Machine (De-Pressurising)
85
Fig.29 Checking the Cooling Oil Level
85
Fig.30 Venting the Machine
86
10.15 Replenishing the Cooling Oil
87
Venling the Machine (De-Pressurising)
87
Fig.31 Replenishing the Cooling Oil
87
Topping up with Cooling Oil and Trial Run
88
Changing the Cooling Oil
89
Fig.32 Changing the Cooling Oil, Oil Separator Tank
90
Fig.33 Changing the Cooling Oil, Oil Cooler
91
Fig.34 Changing the Cooling Oil, Airend
92
Changing the Oil Filter
93
Changing the Oil Separator Cartridge
94
Fig.35 Changing the Oil Filter
94
Fig.36 Changing the Oil Separator Cartridge
95
Condensate Drainage Maintenance
96
Checking Condensate Drainage
96
Cleaning the Condensate Drain
97
Fig.37 Checking Condensate Drainage
97
Fig.38 Cleaning the Condensate Drain
98
Assembling Ssexible Pipe Connections
99
Fig.39 Assembling Flexible Pipe Connections
99
Documenting Maintenance and Service Work
100
11 Spares, Operating Materials, Service
101
Note the Nameplale
101
Ordering Consumable Parts and Operating Ssuids/Materials
101
Kaeser Air Service
101
Service Addresses
102
Spare Parts for Service and Repair
102
12 Decommissioning, Storage and Transport
107
Putting out of Operation
107
Packing
107
Storage
107
Transport
108
Safety
108
Transport with a Forklift Truck
108
Transport Wilh a Crane
108
Fig.40 Transport with a Forklift Truck
108
Disposal
109
Fig.41 Transport with a Crane
109
13 Annex
110
Pipeline and Instrument Flow Diagram (P+I Diagram)
110
Pipeline and Instrument Flow Diagram (P&I Diagram) MODULATING Control
113
Dimensional Drawing
116
Electrical Diagram
120

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