,

SERVICE MANUAL E

Screw Compressor
Model: SM 11/7,5 bar
GL-Nr.: BA-SM11.L-1.9B23.80100-00
Index: 000215

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Part No.:
Serial No.:

Manufacturer:

KAESER KOMPRESSOREN GmbH

D-96410 Coburg' Postfach 2143 Tel. (09561) 640-0 Fax.(09561) 640-130
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Table of Contents
Chapter - Page

1 Technical Specification ........................................ . 1 - 1

1.1 Compressor Package ................................................ . 1 - 1
1.2 Sound Pressure Level . ............................................... . 1 - 1
1.3 Motor ................................... .. .. .. 1 - 1
1.4 Power Supply ....................................................... . 1 - 2
1.5 Pressure Relief Valve' ................................................. . 1-2
1.6 Installation Req uirements ............................................. . 1-2
1.7 Oil Capacities ........., .............................................. . 1 - 2
1.8 Recommended Coolant .............................................. . 1 - 3

I 1.9
1.10
Maintenance Interval for the Electric Motor .............................. . 1 - 3
Dimensional Drawing ................................................ . 1 - 3
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2 Safety Regulations ............................................ . 2-5

2.1 Explanation of Symbols and References ................................ . 2-5
2.2 General Safety Instructions ........................................... . 2-5
2.3 Electrical Safety ..................................................... . 2-6
2.4 Spare Parts .................................................... : .... . 2-6
2.5 Compressed Air Installation ........................................... . 2-7
2.6 Environmental Protection ............................................. . 2-7

3 General ................. ..................................... . 3-8

3.1 Correct use ......................................................... . 3-8
3.2 Incorrect use ........................................................ . 3-8
3.3 Compressed Air Treatment ........................................... . 3-8
3.4 Copyright. ......................................................... .. 3-8

4 Transport ..................................................... . 4-9

4.1 Transport Instructions ................................................ . 4-9
4.2 Packaging .............................. . 4-9

5 Technical Description ......................................... . 5 -10

5.1 Principle of Compression ............................................. . 5 - 10
5.2 Short Description .................................................... . 5 - 10
5.3 Pipe and Instrument Flow Diagram (P & I Diagram) ...................... . 5 - 10
5.4 DUAL Control ....................................................... . 5 - 13
5.5 QUADRO Control .................................................... . 5 - 14
5.6 VARIO Control Mode ................................................. . 5 - 15
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6 Installation ................................................... . 6 -16 I,
6.1 Installation Requirements ............................................. . 6 - 16
6.2 Connection of the Compressed Air Supply .............................. . 6 - 17 ,.I
6.3 Electrical Connection ................................................ . 6 - 17

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Table of Contents Table of Contents

Chapter - Page Chapter - Page

7 Initial Start .................................................... 7 - 18 10 Spare Parts and After Sales Service ... . . . . . . . . . . . . . . . . . . . . . . . . .. 10 - 46
7.1 Points to be Observed before Initial Start ................................ 7 - 18 10.1 Service parts and expendable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10 - 46
7.2 Points to be Observed before Starting the Compressor Package: ........... 7 - 18 10.2 Service and Maintenance Agreement ................................... 10 - 47
7.3 Door Interlock Switch Check ........................................... 7 - 19
Direction of Rotation Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 21
11 Appendix ............................................ 11 - 48
7.4
7.5 Setting up the Motor Overload Trip ..................................... 7 - 21 11.1 Electrical Diag ram .................................................... 11 - 48
Setting the Air Main Pressure Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 21 11.2 Record of Maintenance Work 11 - 64
7.6
7.7 Measures to be taken before Initial Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 22
7.7.1 Pour a small quantity of oil into the air inlet port. . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 22
7.7.2 Running the compressor package in idle ................................ 7 - 22
7.8 Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 23

8 Operation............................ . . . . . . . . . . . . . . . . . . . . . . . .. 8 - 24 ~
..

8.1 Control Panel ........................................................ 8 - 24

8.2 SIGMA controller ..................................................... 8 - 24
8.3 Emergency Stop Pushbutton ........................................... 8 - 24
8.3.1 Function keys .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . .. 8 - 25
8.3.2 Light emitting diodes and plain text display .............................. 8 - 25
8.4 Compressor Package ON/OFF ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 - 26
8.5 Acknowledgement of Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 - 26
8.6 Acknowledgement of Service Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 8 - 27

9 Maintenance .................................................. 9 - 28
9.1 Observe the following during all Maintenance and Servicing Work .......... 9 - 28
9.2 Regular Maintenance ................................................. 9 - 29
9.3 . Opening and Closing the Compressor Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . .. 9 - 30
9.4 Checking the Tension of the V-belts .................................... 9 - 30
9.5 Changing the V belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 - 31
9.6 Cleaning or Renewing the Filter Mat .................................... 9 - 32
9.7 Cleaning or Renewing the Air Filter ..................................... 9 - 32
9.8 Servicing the Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 - 33
9.9 Checking the Pressure Relief Valve on the Oil Separator Tank. . . . . . . . . . . . .. 9 - 33
9.10 Venting the Compressor Package ...................................... 9 - 34
9.11 Oil Filter Change ..................................................... 9 - 35
9.11.1 Removal and replacement of the oil filter ................................ 9 - 35
9.12 Oil Top Up ........................................................... 9 - 36
9.13 Cleaning the Oil Cooler and Air Cooler .................................. 9 - 38
9.13.1 Removing and cleaning the oil/air cooler ................................ 9 - 38
9.14 Oil Change (Oil Separator and Oil Cooler) ............................... 9 - 40
9.14.1 Draining the oil using external pressure source ........................ .. 9 - 41
9.14.2 Adding oil ........................................................... 9 - 42
9.14.3 Draining the all using own compressed air ............................... 9 - 42
9.14.4 Measures for putting back into operation ................................ 9 - 43
9.15 Changing the Oil Separator Cartridge .............................. . . . .. 9 - 43 J'<,
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 Technical Specification
It" Technical Specification

1.4 Power Supply

1 Technical Specification
(see chapter 6.3 for further details)
Mains voltage ....................................... 460 V 3~/PE

1.1 Compressor Package Freq uency ........................................... 60 Hz

Model ........................................... SM 11 Max. mains fusing (slowblow or gl class) ................ 20 A

2
Permissible gauge working pressure ................... 7,5 bar Power supply cable cross-section .................. 4 x 2,5 mm
(CU multicore cable)
Operating temperature, approx................... 75 - 100C
(related to the gauge working pressure and climatic conditions Current flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 15 A
such as humidity in the air and ambient temperature).
Weight ............................................. 170 kg 1.5 Pressure Relief Valve
Drawings: Activating pressure ............................... , .... 9 bar

Dimensional drawing .............................. T 9656

P & I fiow diagram .................. FSM11STL-00018.00 1.6 Installation Requirements
(Pipework and instrument fiow diagram) Max. height above sea level ......................... 1000 m
Electrical diagram ................... SSM11-01021.00 Min. ambient temperature ........... , ............ , .. , .. 3 C
Max. ambient temperature ................... , ......... 40C
1.2 Sound Pressure Level Min. cooling air/inlet air temperature ..................... 3 C
Operational state of the compressor unit: Max. cooling air/inlet air temperature .................... 40C
2
Full load, the compressor unit runs at: rated speed, rated pressure, rated capacity. Air inlet opening , ...................... , ............ . 0,2 m
Setting up conditions: Exhaust air for solution A (see chapter 6.1):
3
Free field measurement Forced ventilation with exhaust fan .................... 2500 m /h at 100 Pa

Measurement to CAGI/PNEUROP PN8 NTC 2.3: Exhaust air for solution B (see chapter 6.1):
Sound Pressure Level ................................. 69 dB (A) Exhaust air used for space heating:
Heating duct w x h . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 200 x 355 mm

1.3 Motor
1.7 Oil Capacities
Drive motor: Total oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 5 I
Rated power ........................................ 7,5 kW
1 After oil change or after long period of storage
Rated speed ....................................... 3600 min-
Amount required to top up the airend .................. 0,1 I
Protection class .................................... IP 54

V-belt set:
Par! number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.2510.0

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 Technical Specification Technical Specification

1.8 Recommended Coolant

KAESER screw compressors are filled with the following coolant. This coolant is highly suit-
able for all operating conditions:

KAESER SIGMA FLUID PLUS

This coolant was especially developed for use in screw compressors. o

Topping up the coolant:

Always use the same brand and type of coolant (see label on the separator tank).
Coolant change and change of coolant type:
The compressor package must be completely drained before refilling with coolant or
changing the type of coolant. As far as is possible, remove all existing scale and deposits
in the cooling system. It is possible that the separator cartridge may have to be changed
soon after changing the type of coolant because of existing deposits that have been freed.
This is caused by the cleaning effect of the new coolant.
KAESER SIGMA FLUID PLUS has the following characteristics:
Viscosity at 40C DIN 51562-1 68 mm 2/s
Viscosity at 100 C DIN 51562-1 10.6 mm 2 /s
Density at 15C DIN 51757 842 kg/m 3
Flash point (COC) DIN ISO 2592 245C
Pour point DIN ISO 3016 -30C
>-
Water separability at 54C DIN 51599 30 min --- i ~-
Very good oxidation stability _-oi
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Good anti-wear properties

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Excellent dispersant and detergent properties
High viscosity index
J====___________ . __.____.cc - -I
Very good demulse properties
,
Low evaporation loss "
A DIN/EN safety specification sheet covering this coolant can be requested from KAESER.
Coolant order number:
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Sigma Fluid Plus 200 I Order No.: 9.1454.0
Sigma Fluid Plus 20 I Order No.: 9.1459.0
Sigma Fluid Plus 4 I
/lll~---r;;:::=:::;;:::~~--T
Order No.: 9.1468.0
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1.9 Maintenance Interval for the Electric Motor II a
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Renew the compressor motor bearing:
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Under normal operating conditions, after ............. 12000 h*
(ambient temperature up to 25C)
Under unsuitable operating conditions, after ........... 6000 h*
(ambient temperature up to 40C)
at the latest after. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3 years
1< service hours

1.10 Dimensional Drawing II.

(see following page)

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 Safety
2 Safety Regulations
Read this service manual carefully and observe cautionary references before putting this
compressor package into operation and before carrying out any maintenance.
2.1 Explanation of Symbols and References
This symbol is placed before all references to safety where danger to
life and limb can occur. It is especially important that these regulations
are observed and that extreme care is taken. For their own protection,
all other users must be informed of these safety regulations. Observe
general safety and accident prevention regulations as well as the
safety regulations laid down in this service manual.
I Attention! I This symbol is placed by text where considerable attention must be
paid so that recommendations, regulations, references and correct se-
quence of work are adhered to and that damage andlor destruction of
the compressor package andlor other equipment is prevented.
This symbol identifies environmental protection measures.
This symbol indicates operations to be carried out by the user.
This bullet identifies listings .
2.2 General Safety Instructions
Work on power driven systems may only be carried out by trained or
specialized personnel.
Work on electrical equipment in the compressor package may only be
carried out by a trained electrician or trained personnel under the
supervision of a trained electrician according to electrical engineering
regulations.
Before work is carried out on electrical systems, carry out the follow-
ing measures in the sequence shown.
1. Switch off the main switch
2. Ensure the main switch cannot be switched on again
3. Check that no voltage is present
Pipework under pressure should be vented or shut off if not stated
otherwise in the service manual.
I Attention! I Any modification or conversion carried out without prior consultation
with KAESER and without KAESER's prior written consent will invali-
date the warranty.
Euro.pean Standards must be observed during installation, operation, maintenance and
repair of the compressor package.
2-5
Safety
Valid national safety regulations must be complied with if the corresponding European
Standards are nor yet incorporated into national legislation.
Users of compressor packages located outside the jurisdiction of European Standards are
obliged to comply with the safety and accident prevention regulations concerning the com-
pressor package that are valid in the country of use. If necessary, corresponding measures
must be taken to ensure compliance with these national regulations before the compressor
package is put into operation.
We also recommend observation of the following:
Allow no open flame and flying sparks in the place of installation.
During any necessary welding on or near the compressor package ensure that sparks
or high temperatures cannot cause fire or explosion.
Ensure that clean air without damaging impurities is fed to the compressor package.
"';i\
, } Do not allow the maximum ambient temperature to be exceeded (see chapter 1.6),
otherwise special measures must be agreed between the manufacturer and the cus-
tomer.
Carry out oil changes according to the service manual.
Do not mix oils of different types.
Maintain and monitor the operating temperature to manufacturer's specifications to
avoid build-up of condensate in the oil circulation.
Use only oils recommended by the manufacturer.
If maintenance work is carried out on any part of the oil circulation system, top up the
oil in the oil separator tank to the maximum level, run the compressor and keep it
under constant observation for a short period. Check the oil level again and top up
with oil to replace the oil taken up by the piping and the cooling system.
Change the filter cartridge in the oil separator tank as soon as the pressure drop
across the cartridge reaches 1 bar. Check constantly.
2.3 Electrical Safety
The electrical installati~n of the compressor package must conform to the requirements of
European Standards EN 1012-1 and EN 60204-1. The regulations of the local electricity
authority must also be complied with.
For this reason, the following measures must be carried out by the user to ensure the
safe operation of the compressor package:
Compressor packages fitted with a drive motor of 3 kW or above and a current rating
of 16 amperes or above must be fitted with with a lockable main switch (see EN
60204-1, P 5.3) and mains fuses.
The type of main switch used is dependent on the power consumption of the drive
motor (see chapter 1.4 for value).
The type of protective circuit breaker used is dependent on the starting characteristic
of the drive motor.
See chapter 1.4 for recommended cable cross-sections and fuses.
2.4 Spare Parts
Original KAESER parts are designed and matched to meet the technical requirements of
the air system. Only the use of original KAESER spare parts and KAESER SIGMA cooling
, 1 oil guarantees safe and reliable operation.
~./
2-6
 ;

Safety General

2.5 Compressed Air Installation 3 General

If a compressed air installation is extended or changed, check the blowoff pressure of the
pressure relief valves on the air receiver tanks and in the pipework before the new com- The service manual must always be available for use at the location of
pressor package is installed. the compressor package.
If the blowoff pressure is too low, fit a pressure relief valve with correspondingly higher
blowoff pressure.
3.1 Correct use
2.6 Environmental Protection The compressor package is intended solely for the purpose of generatin~ compressed air,
Any other use is considered incorrect. The manufacturer cannot accept ~Iability for any
Condensate drainage consequential damage caused by such incorrect use; the user alone IS liable for any risks
ioou~. , II' d'
The condensate accumulating during compression must be fed via a Correct use of the compressor also encompasses adherence to the Insta alian, Isassem-
suitable drainage system into special canisters and disposed of ac- bly, commissioning, operational and maintenance conditions laid down by the manufac-
cording to environmental regulations. turer.
This compressor package may only be used for industrial purposes.
Lubricants I consumable materials I replacement parts

Ensure that all lubricants, consumable materials and replacement 3.2 Incorrect use
parts accumulating during operation and servicing of the compressor
package are disposed of according to environmental'regulations. Never direct compressed air toward persons. Compres~ed air is a con-
centrated form of energy and as such is dangerous to hfe.
The following points must be observed when handling lubricating and
cooling materials:
3.3 Compressed Air Treatment
Avoid contact with skin and eyes.
Never use compressed air from oil injected compressor ~ackag,:s for
Do not inhale vapours and oil mist.
Do not eat or drink when handling such materials. breathing purposes and production methods where the .alr has ~I~ect
contact with food, without subjecting the compressed air to additional
Fire, open flame and smoking are strictly forbidden.
treatment.

3.4 Copyright
All rights reserved.
No part of this publication may be reproduced or utilized in any form or by any mea~s~ ,
o electronic or mechanical, including photocopying and microfilm, Without prior permission In
writing from KAESER COMPRESSORS.

3-8
2-7
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Transport Construction and Operation

4 Transport 5 Technical Description

4.1 Transport Instructions 5.1 Principle of Compression

We recommend a fork lift truck or lifting equipment for transporting the compressor pack- The stationary compressor package is fitted with a single stage, oil-injected airend. Two
age to avoid damage to the cabinet and framework. rotors the driven male rotor and the female rotor, both mounted in roller bearings, are
fitted ;'n the airend. As the rotors rotate, air is drawn into the upper side through the inlet
c;- port and is compressed on the,lower side. The oil that is injected into the lower side ab-
sorbs heat generated by compression, prevents metallic contact between the rotors, seals
the rotors and the housing from each other and also lubricates the roller bearings. The
compressed air and oil mixture leaves the airend via the discharge port.
A
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6

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min. 800mm

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2 3 4 5
1

1 Drive shaft 4 Male rotor

2 Oil injection 5 Female rotor
3 Discharge port 6 Air inlet port

5.2 Short Description

Attention:
Do not exert any side forces on the compressor The compressor block is driven via V-belts from an electric motor.
unit when transporting with lifting equipment! An oil separator cartridge is fitted into the oil separator tank allowing practically oil free
compressed air supply.
The regulation of the compressor package ensures that compressed air is generated
within set pressure limits.
4.2 Packaging A safety function protects the compressor package against failure of important systems
A factor deciding the type of packaging is the transport route. The packaging conforms to through automatic shut-down.
regulations laid down by the German Federal Association of Wood, Pallet and Export Pack- The fan ensures ventilation of the compressor package and also sufficient cooling air for
aging (HPE), and by the German Machinery and Plant Association (VDMA), if not otherwise
contractually agreed. the air-cooled oil and air cooler.

Dispose of packaging according to environmental regulations and re- 5.3 Pipe and Instrument Flow Diagram (P & I Diagram)
cycle where possible.
(see following pages)

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Air filter

2 Inlet valve
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10
Oil temperature controller
Oil fitter
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2.1 Oil filler w'lth plug
11 Oil cooler ::l
3 Drive motor CI
12 Minimum pressure check valve
4 Airend ::l
13 Air cooler C.
4.1
4.2
Strainer
Pressure switch - Wrong direction of rotation 16 Dirt trap
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17 Nozzle (1)
5.2
6
6.1
PT100 sensor

OiL separator tank

Pressure gauge
18/19 Combined control/vent valve
18 Control valve
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19 Vent valve ::l
6.2 Hose coupling (oil end)
20 Shut-off valve - Vent line
6.3 Hose coupling (air endl
21 Silencer
6.6 Shut-off valve - Oil drain
59.1 Pressure measuring transducer Air main pressure
6.9 Oil level sight glass: minimum/maximum oil level

1 Pressure relief valve

P+I OialJam le~end

(]I ~::. ~~u4.11'99 SM 11 FSM11STL-00018.00 Blatt z

Gop,. Morrin ,.
I And.rung O.tum N.... No,.. Er.. ~ dur<h, fro.I, fu~
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 Construction and Operation Construction and Operation

5.4 DUAL Control 5.5 QUADRO Control

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.8 Idle ~ . Standstill
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Time .. I TIme I_
~rise I I
In DUAL Control mode (combined idle and start-stop) the compressor normally runs at I I
full-load, idle or standstill. ~deCay
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The controller regulates the compressor package between load and idle. Running period I I I
If the compressorpackag~ runs in idle for longer than the preset period (1) to (2), for Idlel I I I
ex~mple t1 = 6 min, the drive motor IS stopped completely (2). When the lower switching standstill period I I I
~olnt Pm!n (3) IS reached the compressor package is automatically started again. Pressure Run -on period I --+l+- --+l+- I
rises to the upper switching point Pmax (4), and the compressor package switches to idle. If
the pressure falls again to, for example, Pm!n (5) within a shorter period (4) to (5) then the
compressor is automatically switched from idle to load. ' Stop point for the running period or idle I standstill period
Pmax upper switching point

Pmin lower switching point

~rise
pressure rise time (the time during which the air main pressure rises
from the lower to the upper switching point)
ipdeCay
pressure decay time (the time during which the air main pressure decays
from the upper to the lower switching point)
-',
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Functional description
Two fixed periods - the running period and idle/standstill period - are taken a~ the.crit-
erium for selection of the operating mode of the compressor package when the air main
pressure reaches the upper switching point. These two periods are set according to the
maximum permissible starting frequency of the drive motor.
The running period starts every time the compressor package is switched .on. It lasts as
long as the drive motor runs and stops when the compressor package sWitches to stand-
still.
The idle/standstill period starts every time the operating mode changes from full load to
idle. It runs during idle and also when the compressor package is switched to standstill
after the idle period. It stops when the compressor package switches to full load.
Every switching off point is delayed by the run-on period, during which time the com-
pressor package vents.

.,
5 -14 , .
:.1'
5 - 13
I'
 Construction and Operation Installation

The following switching cycles are possible:

6 Installation
If the air main pressure decays to the lower switching point, the compressor package
switches to full load (1) irrespective of its previous operating mode. If the drive motor
was at a standstill the opening of the inlet valve is delayed to allow an unloaded com-
pressor package start.
6.1 Installation Requirements
If the air main pressure rises to the upper switching point and the running period has
already expired, the compressor package is switched off after the run-on period has
expired (2).
I Attention! I Ensure that the compressor package is level. . .
The floor must be solid with good loading characteristics.
If the air main pressure rises to the upper switching point before the running period See chapter 1,. 1 for the weight of the compressor package.
has expired then the pressure decay time of the previous switching cycle is taken as
the criterium for the selection of the operating mode: Safe operation of the compressor package is only ensured if the ambient temperature re-
mains within the limits stated in chapter 1.6).
- If the pressure decay time tpd"ay was longer than the period set for the idle/standstill
period, the compressor package is switched to standstill after the run-on period has If the compressor package is used in the open, take care that it is protected against the
expired (3). direct rays of the sun and against the ingress of dust and rain.
- If the pressure decay time tpd"ay was shorter than the period set for the idle / stand- Install the compressor package as detailed in the following diagram. Keep to the minimum
still period, the idle mode is selected (4), that is, the inlet valve closes and the com- distances shown to allow free access to the compressor package.
pressor is vented with running motor. When the running period expires the com-
pressor package switches to standstill only after the run-on period has also Adequate ventilation of the compressor space is ensured only if the minimum values (see
expired (5). chapter 1.6) are adhered to.

5.6 VARIO Control Mode

Functional description:
The idle period is automatically lengthened or shortened by the variable idle control in rela-
tion to the number of motor starts. The number of motor starts during the preceding hour
*'- A
Exhaust ventilator
a
a
are measured. 1;:
A high switching frequency leads to longer idle periods. Exhaust
.s
E
A low switching frequency leads to shorter idle periods. duct
B
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Air inlet
opening
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I
I
"- , min. E
\ 500
I \
I \

800
min. 2200
Meas urements in mm

5 - 15 6 - 16
 p~k/ti)
Installation -1 -
I nitial Start

Solution A: forced ventilation

7 Initial Start
The exhaust fan fitted in the compressor space must provide adequate ventilation relative
to the size of the compressor package (see chapter 1.6).
Solution B: exhaust air used for space heating 7.1 Points to be Observed before Initial Start
The hot air is forced through a duct into the room to be heated. Every compressor package is given a test run in the factory and carefully checked before
shipment. The test run confirms that the compressor package conforms to the specifica-
IAttention! I The choice of exhaust air ducling, length of ducling and number
of bends can affect the compressor cooling system and must be
tion data and runs perfectly. However, independent of the checks made at the factory, the
compressor package could be damaged during transport. For this reason, we recommend
approved by the manufacturer. that the compressor package' is examined for such possible damage. Observe the com-
pressor package carefully during the first hours of operation for any possible malfunction.
Reliable, safe operation of the compressor package is only warranted if the temperature
limits (see chapter 1.6) of the air in the compressor space are kept to. IAttention! I Important functional components in the compressor package (such as
minimum pressure/check valve, pressure relief valve, inlet valve and
combination valve) are adjusted and fitted to precise setting up regula-
6.2 Connection of the Compressed Air Supply tions. Alterations to these components are not allowed without previ-
ous consultation with the manufacturer.
The unit is set up ready to operate. Connect the discharge outlet to the user pipework
using a flexible connection hose.
The minimum pressure/check valve, pressure relief valve and inlet I

valve are spring biased.

6.3 Electrical Connection I
i
The connection to the main power supply and the protective measures 7_2 Points to be Observed before Starting the Compressor Package:
required are to be carried out by an authorized electrician to the re-
quirements of European Standard EN 1012-1 and EN 60204-1 and to
,I
NON-OBSERVANCE OF THESE OR OTHER INSTRUCTIONS (WARN- I
the regulations of the local electricity authority. ING, ATTENTION) CAN LEAD TO ACCIDENTS CAUSING INJURY TO
The compressor package is wired ready for connection to the main power supply as de-
PERSONS OR DAMAGE TO EQUIPMENT. I
tailed In the electncal diagram. Feed the supply cable through the PG fitting on the base
frame and the control cabinet (see chapter 1.10).
The compressor package starts automatically after a power failure if
the air main pressure is lower than the pressure set on SIGMA CON-
,I
I Attenlion! I The user of a compressor is obliged to carry out the following
TROL. I
measures: Do not operate the compressor with open access doors as injury to ~
Compressor packages fitted with a drive motor greater than 3 kWand
persons could occur through the drive belts and electrical equipment. i
I
a current rating greater than 16 ampere must be installed with a lock- Remove all packaging materials, tools and transport securing devices on and in the !
able main isolating switch and main fuses. "l 0
-:1<)
10"
compressor package.
I
The type of main switch used is dependent on the power consumption It is expected that the operator employs safe working techniques and that all lawful
of the drive motor (see chapter 1.4 for the value). operating and safety regulations are followed when operating this compressor pack-
age.
I
The type of protective power circuit breaker used is dependent on the
I
starting characteristic of the drive motor. The user of this compressor package is responsible for its safe operating condition.

Do not operate this compressor package in spaces where very dusty conditions, toxic
or inflammable gases could exist. ,I
IAttention! I ~he cross-section of the supply cable and the fuse ratings are speci- I,
fied to DIN VDE 0100 part 430 and 523 for an ambient temperature of Do not connect the compressor package to a supply voltage other than that stated on
the nameplate.
30 'C. For other operating conditions, e.g. higher ambient tempera-
tures or longer supply lines (over 50 m) check and determine the
cross-section of the cable and the fuse ratings according to Do not install the compressor package in a space subject to freezing temperatures.
The air temperature conditions at the air-intake must be complied with (see chapter
DIN VDE 0100 and local electricity authority regulations. 1.6).

See chapter 1.4 for recommended cable cross-sections and fuses. If an exhaust air duct is installed, the cross section of the duct must be equal to or
larger than the cooling air outlet of the compressor package and may not exceed the
permitted pressure loss prescribed by the compressor manufacturer.

During installation of the compressor package, ensure that a distance of at least 0.5 m
is kept between the air intake of the package and any wall.
I 'T'
).1 .'
, f V

6 - 17 7 - 18
 Initial Start Initial Start

0" Check the oil level in the oil separator tank (see chapter 9.12). Visual door interlock switch check
Check that the air end rotates in the correct direction (see chapter 7.4). 0" Check that the interlock switch operates smoothly by opening and closing the left-
0" Check the tension olthe V-belts (see chapter 9.4). hand access door.

0" The shut-off valve (6.6, see chapter 5.3) must be closed. IAttention! I If the actuator (3) at the door interlock is incorrectly aligned, inadver-
tent shutdown of the compressor package can occur.
0" The shut-off valve (20, see chapter 5.3) must be open.

Carry out the following work only when power is removed from the The actuator (3) should align with the door interlock switch (1) without
compressor package. binding against the sides of the interlock switch when the access door
is closed. '
Check ali screws on the electrical connections for tightness (carry out
this check again after 50 operating hours). If necessary, re-align the actuator (3).
0" Loosen the bolts (4).
This compressor package is fitted with a running -in oil filter. Replace the filter after the
0" Align the actuator (3) so that it glides smoothly into the interlock switch (1).
running-in period 01200 hours has elapsed (see chapter 9.11).
I]) 0" If necessary, use shims to help align the actuator (3) with the interlock switch (1). I
7.3 Door Interlock Switch Check 0" lighten the bolts (4) again. ,I.
I.
It is not permitted to operate the compressor package without a cor- I
rectly functioning door interlock switch.
6
I
2

2
I
3
Ii 4 II
/; ~

1
~
1

5 ,III
.,
.~
1
'I
I
t
1
1 Door inter/ock switch
2 Clamping nut
3 Actuating element
4
5
6
Bolt
Frame
Access door
il
!I
I
1 Door inter/ock switch Functional check of the interlock switch

I Attention! I A functional check of the door interlock switch must be made after in-
itial start.

0" Start the compressor package (see chapter 8.4).

0" Open the left-hand access door - the compressor package will shut down immedi-
ately if the door interlock switch functions correctly.
0" Close the left-hand access door.
0" Reset the alarm message by pressing the acknowledge (reset) key (11, see
chapter 8.3.1) on SIGMA CONTROL.
The compressor package is now ready to start again. I:
i

:1
7 - 19 7 - 20
.II',
i'

.1
 1
Initial Start Initial Start

7.4 Direction of Rotation Check 7.7 Measures to be taken before Initial Start
IAttention! I The compressor package is wired for connection to a clockwise phase
sequence.
Take the following measures before initial start, after an oil change or a shutdown period of
three months or longer:

A check of the direction of rotation can be made by testing the phase sequence.
7.7.1 Pour a small quantity of oil into the air inlet port.
Arrows showing the direction of rotation are located on the motorand on the air end hous-
ing. Switch off and lock out the main switch.
If the direction of rotation is incorrect. change over the supply conductors L1 and L2.

I Attention! I If the air end rotates in the wrong direction, the compressor package is Do not add oil unless the compressor package is completely vented.
automatically shut down by the pressure switch (4.2, see chapter 5.3).
See chapter 9.10 to vent the compressor.
7.5 Setting up the Motor Overload Trip
Disconnect the supply voltage to the compressor package by switch-
r,)~
;
~
u Unscrew the filler plug (1) on the inlet valve (2) and pour the prescribed quantity of oil
(see chapter 1.7) into the airend.
ing off and locking out the main switch before any adjustments are I u Turn the airend counterclockwise by hand using the belt pulley.
carried out on the compressor package. See chapter 2.3 for the main
switch.
u Screw the plug back in again.

The trip is set to the standard adjustment at the factory. IAttention! I This oil must be of the same type as used to run the compressor {see
label near the oil filler plug on the oil separator tank}.
Compressor motor: star- delta start
If no additional oil is available then remove the required amount of oil
In the star-delta configuration the phase current is fed via the motor overload trip. This
from the oil separator tank. See chapter 9.14 for this procedure.
phase current is 0.58 times the rated motor current.
See motor nameplate for the rated motor current. If the compressor package was shut down for longer than 12 months,
Value: further measures must be taken before putting it back into operation.
Consult the manufacturer first.
To prevent the overload circuit breaker from triggering (because of voltage fluctuations,
temperature influences or component tolerances), the set value can be up to 15% higher u Open the shut-off valve between the compressor package and the air main.
than the arithmetical phase current.

1
1 Rller plug
2 2 Inlet valve

7.7.2 Running the compressor package in idle

1 Motor phase current adjustment At initial start run the compressor package in idle for 20 seconds by pressing the load/idle
2 Reset button key (5, see chapter 8.3.1).
This measure ensures that the compressor package has sufficient time to flood the oil cir-
culation.
7.6 Setting the Air Main Pressure Threshold
The air main pressure threshold is preset at the factory. It can be changed in
SIGMA CONTROL to match customer's operational requirements if the password is known.
For further details, consult the SIGMA CONTROL service manual.

!
7 - 21 7 -22
 ---I
I

Initial Start Operation

7.8 Checklist 8 Operation

u Is the floor at the place of installation solid and level?
OyesOno
8.1 Control Panel
u Is the space large enough for the compressor package or its components?
o yes 0 no
u Are inlet and exhaust air apertures available in sufficient size and number?
o yes 0 no
u Are all components of the compressor package easily accessible?
o yes 0 no
u Is the power supply cable of sufficient cross-section? 1
(have electrical connection carried out by qualified electrician or company familiar with
local conditions) 'I
2
o yes 0 no II
u Is a shut off valve fitted by the user? II
,!
o yes 0 no ;1
i:
u Is a flexible connecting hose or axial compensator fitted between the compressor !!
package and the air main? 'i
I

o yes 0 no I
u Have all screws, bolts and electrical connections been checked for tightness?
1 SIGMA CONTROL
I
~I
o yes 0 no 2 EMERGENCY STOP pushbutton i
I
u Has the oil level in the oil separator been checked?
II
OyesOno 8.2 SIGMA controller I
I
u Is a main switch fitted (suited to the motor starting characteristics)? The SIGMA controller (1) is fitted in the control cabinet in the compressor package and
o yes 0 no serves as the control panel. It has 11 keys and 9 LEDs. Operation of the compressor pack-
age is determined by the settings programmed into the controller.
u Has the setting of the drive motor overload current trip been checked?
Further details on individual function keys, LEDs and plain text display relating to possible
OyesO no alarms and service messages, display of events, etc. are given in the service manual sup-
u Have you ensured that there are no other air components located in the exhaust air flow plied for the SIGMA CONTROL controller.
of the compressor package?
o yes 0 no 8.3 Emergency Stop Pushbutton
u Have service personnel been instructed on safety regulations? The Emergency Stop pushbutton shuts down the compressor package immediately.
o yes 0 no If the Emergency Stop pushbutton is pressed because of an existing hazard, then this
must be eliminated before the compressor package is reset. To accomplish this the follow-
ing procedure must be carried out:
u Unlatch the Emergency Stop pushbutton by turning in the direction of the arrows.
u Acknowledge the alarm message on the controller by pressing the acknowledge
(reset) key. (function keys see chapter 8.3.1.)
I
'!'I
!:

7 - 23 8 - 24
I Operation Operation

8.3.1 Function keys 8.4 Compressor Package ON/OFF

IAttention! I Do not switch the the compressor package on and off with the main
switch. The compressor must always be switched ON and OFF with
7
11 keys (1) and (2).
8
10 9 Local ON:
6
u Switch on the main switch.
1
The controller carries out a sell-test. The sell-test sequence is visible in the display (12).
5 2 Afterwards, the green LED (16) illuminates permanently.
u Press the ON key (1)- LED (19) illuminates. I
The compressor status is indicated by LEDs (17) and (18):
,I
I
4 3 I Attention! I If LED (19) is illuminated and both LEOs (17) and (18) are extinguished
1 ON key ("I"') 6 Menu scroll - DOVVN key
the compressor package is at standstill but on duty. II
2 OFF key ("0") 7 Menu scroll - UP key
3 TImer ON/OFF key 8 The compressor package can start at any moment. I,
Escape key ,
4 Remote ON key 9 Return key
5 Load/idle key 10 Info - event key Local OFF:
'i
I
11 Acknowledge (reset) key u Press the OFF key (2) - LED (19) extinguishes.
u Switch off and lock out the main switch.
8.3.2 Light emitting diodes and plain text display See chapter 2.3 lor details 01 the main switch. I
8.5 Acknowledgement of Alarms
13
II an alarm occurs the compressor package is shut down immediately and the red LED 'I
14 (13) on SIGMA CONTROL flashes. I
12
15 The bottom line in the display (12) shows the actual lault causing the alarm.
A list 01 alarms that may occur during operation is included in the SIGMA CONTROL I
16 19 service manual. !
'III
17 u Remove the lault.
18 I;J) () u Acknowledge alarm with the reset key (11) - LED (13) extinguishes. I!
The compressor package is now ready to start again.

20 21 I Attention! I If the compressor was shut down with the EMERGENCY STOP push-
button, then reset by rotating the latched pushbutton in the direction of
12 Four-line display 17 Load LED the arrow before acknowledging the alarm.
13 Alarm LED 18 Idle LED
14 Communication alarm LED 19 Compressor ON LED
15 Warning - maintenance LED 20 Remote ON LED
16 Power ON LED (to controller) 21 TImer ON LED
i;
,i
"

i.1

i
J I'

I
8 - 25 8 -,26 'I!
.:,
:i"
.11
 Operation Maintenance

8.6 Acknowledgement of Service Messages 9 Maintenance

When maintenance is due the yellow LED (15) on SIGMA CONTROL flashes.

I Atlention! I Before any maintenance is due an initial warning is displayed to allow 9.1 Observe the following during all Maintenance and Servicing Work
coordination of service and maintenance personnel and provision of
necessary servicing materials. (lubricants, spare parts, etc.). Work On power driven systems may only be carried out by trained or
specialized personnel.
Maintenance due is shown in the display (12).
A list of service messages that may occur during operation is included in the SIGMA Work on electrical equipment may only be carried out by a qualified
CONTROL service manual. electrician or trained personnel under the supervision of a qualified
P" Carry out the maintenance work. electrician according to electrical engineering regulations.

P" Acknowledge service message with the reset key (11) - LED (15) extinguishes. The compressor package restarts automatically after a power failure
(standard setting).
IAtlention! I When the respective maintenance has been carried out, the remaining Condition: the air main pressure is lower than the pressure set on the
interval period (programmed interval until the next maintenance is due)
must be reset.
o SIGMA CONTROL.

Switch off and lock out the main switch before attempting any mainten-
Detailed information on resetting service counters is to be found in the service manual for ance work (see chapter 2.3 for the main switch).
SIGMA CONTROL.
Ensure that no maintenance personnel are working on 'the compressor
package, that all panels are screwed back on again and that all access
doors are closed before starting the compressor.

See chapter 8.4 to start the compressor package.

I Attention! I The venting nozzle required to vent the oil separator tank (for mainten-
ance work such as topping up the oil, oil change and filter change) is
fitted to the hose coupling (3, see chapter 9.10).

Carry out a visual and functional check of the door interlock switch
after any maintenance and servicing work.

See chapter 7.3 for details.

o The following points must be observed when handling lubricating and
cooling materials:

Avoid contact with skin and eyes.

Do not inhale vapours and oil mist.
Do not eat or drink when handling such materials.
Fire, open flame and smoking are strictly forbidden.

Ensure that all lubricants, consumable materials and replacement

parts accumulating during operation and servicing of the compressor
pa"ckage are disposed of according to environmental regulations.

I
Iii
i
,I'
I
I

8 - 27 9 - 28
 Maintenance Maintenance

9.2 Regular Maintenance 9.3 Opening and Closing the Compressor Cabinet

Interval Work to be done See chapter To open:

24 h after initial start Check the tension of the V-belts It>" Open the access door (1).
9.4
It>" Pull the locking lever (3, photo A) outwards, turn 90' in the direction of the arrow and
50 h after initial start . Check all electrical connections for tightness latch onto the frame.
200 h after initial start Change the oil filter 9.11 It>" Lift the panel (2) and remove.
Weekly Check the oil level 9.12 To close:
Check the filter mats for clogging 9.6 It>" Turn the locking lever (3) to its initial position.
500 h Check the tension of the V-belts 9.4 It>" Attach the panel (2) making sure that it latches.

Clean the air filter' 9.7 It>" Close the access door (1).

1000 h Check the oil cooler and air cooler for clogging 9.13 Close all access doors and panels correctly before starting the com-
pressor package.
Clean or renew the filter mats' 9.6

2000 to 3000 h or an- Change the oil filter' 9.11

nually at the latest
Change the air filter' .
9.7

8000 to 9000 h" Change the oil' 9.14

Change the oil separator cartridge' 9.15

Annually Check all electrical connections for tightness

Check the pressure relief valve 9.9 A

6000/12000 hours or Have the compressor motor bearings renewed 9.8
after three years at the by the KAESER Service'
latest

The maintenance period can vary depending on the motor switching frequency and
environmental conditions . o
Only applies to Sigma Fluid Plus (see label on oil separator). If other oils are used con-
tact an authorized KAESER service agency. National regulations concerning oil changes
must be strictly adhered to. 3

We urgently recommend that a record is kept of all servicing done (see chapter 11.2) and
1 Access door
that the compressor package - especially safety devices - are checked annually by an
2 Cover panel
authorized KAESER service agency. 3 Unlocking lever

9.4 Checking the Tension of the V-belts

It>" Switch off the compressor package (see chapter 8.4).

Switch off and lock out the main switch to prevent accidents during
maintenance.

Check the tension of the V-belts after the first 24 hours of operation and then every
500 hours of operation.
\)

9 - 29 9 - 30
, ,I
~
 Maintenance Maintenance

9.6 Cleaning or Renewing the Filter Mat

Check the filter mat weekly for clogging and clean, or renew if necessary as detailed in the
regular maintenance table (see chapter 9.2) .

~~~+--2 D' Switch off the compressor package (see chapter 8.4).
1
Switch off and lock out the main switch to prevent an accidental com-
pressor run.

ol-c:--- 3

~--1
1 Hexagonal nut
2 Hexagonal nut Of)
3 Marking pin
'---- 2
The V-belt tension is automatically adjusted within a limited range by the pressure spring
of the belt tensioning device.
Re-tension the V-belts if they have stretched to the point where the marking pin (3) is
located at the top end of its indicator slot.
D' Loosen the hex nut (2).
1 Riter mat
OJ Re-tension the V-belts with the hex nut (1) until the marking pin (3) is located at the 2 Holding frame
bottom end of its slot.
D' Remove the holding frame.
D' lighten the hex nut (2).
D' Open and close with a screwdriver.
9.5 Changing the V belts D' The clamping frame sits securely after turning the snap fasteners by a 14 turn.
D' Switch off the compressor package (see chapter 8.4). Cleaning:
Rinse the mat in water of approximately 40C, if necessary with a mild washing powder.
Switch off and lock out the main switch to prevent accidents during The mat can also be tapped with the palm of the hand, cleaned with a vacuum cleaner or
maintenance.

D' Loosen the hex nut of the swing frame adjustment (2, see chapter 9.4)
u blown out with compressed air. Rinse out oily dust with warm water using a mild solvent
additive.

D' Screw the hex nut (1, see chapter 9.4) until the V-belts are loose. I Attention! I If the mat is heavily soiled or has been cleaned often (max. 5 times),
replace it.
D' Remove the V-belts.

I Attentionl I It is essential that replacement belts are all precisely the same length
9.7 Cleaning or Renewing the Air Filter
(each set) and absolutely oil- proof. For this reason we recommend
that only original KAESER drive belts are used. Clean the air filter after every 500 service hours.

[>" Place the new V-belts over the motor and compressor pulleys without straining them. D' Stop the compressor unit (see chapter B.4).

D' Set the V-belt tension (see chapter 9.4). Switch off and lock out the main switch to prevent an accidental com-
pressor run.
I Attentionl I Check the V-belt tension after two hours of operation and then again
after 24 hours of operation, as experience shows that the belts stretch
mostly during this period.

9 - 31 9 - 32
 Maintenance Maintenance

9.10 Venting the Compressor Package

[7 Shut down the compressor package (see chapter 8.4).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.

[7 Close the shut-off valve between the compressor package and the air main.
The oil circulation vents automatically.

1 Air filter Venting the oil separator tank:

2 Air filter cap
3 VWng nut for opening air filter housing
4 Air filter cartridge 2 11

To open the air filter housing: 6

[7 Unscrew the wing nut (3) and remove the air filter cap (2) and the filter cartridge (4).
[7 Clean the air filter cap and sealing surfaces. 3

Cleaning the air filter cartridge (4) by tapping: 4

[7 Tap the air filter cartridge several times on the front with the ball of the hand.
I Attention! I Do not use force otherwise the air filter cartridge may be damaged. 1
[7 Clean all sealing surfaces.
Cleaning the air filter cartridge with compressed air:
[7 Blow dry compressed air at a pressure of not more than 5 bar at a slant from the in-
side to the outside of the air filter cartridge surfaces.

IAttention! I Do not clean the air filter cartridge with fluids. If the air filter cartridge
is heavily contaminated or was already cleaned several times (max.
5
five times). renew. ,
.1
To close the filter housing: 9
[7 Insert the filter cartridge (4) and replace the air filter cap (2).
[7 Screw on the wing nut (3) tightly. 7

9.8 Servicing the Electric Motor o 10

Compressor motor:
The electrical motor bearings are permanently greased.
I Attention! I Have the motor bearings replaced using the KAESER Service in ac-
cordance with the maintenance schedule (see chapter 1.9). 1 Shut - off valve 4 Filler plug 8 Screwed sealing plug
A shut (oil top - up) (oil cooler)
9.9 Checking the Pressure Relief Valve on the Oil Separator Tank Bopen 5 Oil separator tank 9 Shut -off valve - oil drain
2 Pressure gauge 6 Plug - in nipple 10 Hose coupling
To check the operating pressure of the pressure relief valve the final pressure of the 3 Hose coupling 7 Oil level mini -/maximum 11 External pressurization
compressor package must be increased above the pressure parameter entered in the
controller. [7 The pressure gauge on the oil separator tank must indicate zero bar.
See chapter 1.5 for the operating pressure of the pressure relief valve.
Oil mist can escape when the oil separator tank is vented.
I Attentionl I The pressure relief valve must be checked by an authorized KAESER
service agency when the interval quoted in the regular maintenance
table (see chapter 9.2) has expired.
[7 Insert the nipple (6) in the hose coupling (3) on the oil separator tank (the residual
pressure in the oil separator tank escapes).
Detailed information is to be found in the service manual for SIGMA
CONTROL. [7 Remove the nipple (6) from the hose coupling (3).

9 - 33 9 - 34
! i

Maintenance Maintenance

Venting the air-cooler:
When the compressor package is vented, the air-cooler and the pipe-
work up to the minimum pressure check valve are still under pressure.
For this reason the compressor package must be isolated from the air
main (close the user's shut-off valve). If a shut-off valve is not avail-
able, vent the air main completely.
u Carefully remove the pipe fitting (4, see chapter 9.13). The air-cooler vents.
u TIghten the pipe fitting again.
u Spin off the used or contaminated oil filter counter-clockwise and catch escaping oil
in a suitable container.
Dispose of the used filter and used oil carefully according to environ-
mental regulations.
u Clean the sealing faces carefully with lint free cloth.
u Lightly oil the gasket of the new oil filter before screwing into position.
u Spin on the new oil filter ,clockwise by hand until the gasket fits tightly.

Close all access doors and panels correctly before starting the com-
IAtlention! I Do not use a tool as this may cause damage to the oii filter and the
gasket.
pressor package.
u Check the oil level (see chapter 9.12).
u Open the shut-off valve between the compressor package and the air main.
9.11 Oil Filter Change o
Carry out a trial run.
Hot oil; beware of scalding.
When the operating temperature is reached (see chapter 1.1) shut
During the running in period. a running-in oil filter cartridge is fitted to clean the oil sys- down the compressor package (see chapter 8.4) and lock out the main
tem. . switch to prevent an accidental compressor run.

I Atlention! I Replace the running - in oil filter cartridge with a standard oil filter car- Carry out a visual check for leaks.
tridge after approximately 200 operating hours.

A further filter change is recommended after the interval quoted in the regular maintenance
table (see chapter 9.2) or when the corresponding service message is displayed on SIGMA
CONTROL (see chapter 8.1). The filter must be changed after every oil change.
9.11.1 Removal and replacement of the oil filter
u Shut down the compressor package under full load (see chapter 8.4).
9.12 Oil Top Up
Check the oil level weekly with the oil level sight gauge when the compressor unit is shut
down. If necessary, top up the oil to the maximum level. To do this, it is imperative that the
compressor unit is switched off under full load conditions and that the oil level is allowed to
settle for five minutes. Do not exceed the maximum level.
u Shut down the compressor package under full load (see chapter 8.4).

Switch off and lock out the main switch to prevent an accidental com- Switch off and lock out the main switch to prevent an accidental com-
pressor run. pressor run.
o
Before opening or removing pressurized components (pipes, hoses,
Before opening or removing pressurized components (pipes, hoses,
tanks, etc.) it is imperative that the compressor package is completely
tanks, etc.) it is imperative that the compressor package is completely
depressurized.
depressurized.
u Venting the compressor package (see chapter 9.10).
u Venting the compressor package (see chapter 9.10).

1 Oil filter cartridge

2 Turn in this direction to unscrew the cartridge

9 - 35 9 - 3(3
-,-, --

Maintenance Maintenance

11 9.13 Cleaning the Oil Cooler and Air Cooler

2
The oil cooler and air cooler must be checked for clogging regularly. Heavy clogging may
6 cause high temperatures in the oil circulation.
See regular maintenance table for cooler service interval (chapter 9.2).
3
u Switch off the compressor unit under full load (see chapter 8.4).
4
Switch off and lock out the main switch to prevent an accidental com-
pressor start.
1
Before opening or removing pressurized components (pipes, hoses,
tanks, etc.) it is imperative that the compressor package is completely
depressurized.

u Venting the compressor package (see chapter 9.10).

5
9.13.1 Removing and cleaning the oil/air cooler

9 1

7 Ilfli'IIil!---=-~ 1

-Ic--- 10 =
~---2

8
3
4 -_-./'
I
1 Shut - off valve 4 Filler plug 8 Screwed sealing plug II
A shut (oil top - up) (oil cooler)
Bopen 5 Oil separator tank 9 Shut-off valve - oil drain
.2 Pressure gauge 6 Plug - in nipple 10 Hose coupling
3 Hose coupling 7 Oil level mini -Imaximum 11 External pressurization
1 Allen screw i

u Unscrew the oil filler plug (4) on the oil separator tank. I
L;' ()
2 Hose screw fitting I!I!
u Top up the oil to the maximum mark. 3 Pipe screw fitting
u Check the sealing ring of the filler plug (4) for damage and then replace the filler 4 Pipe screw fitting
plug (4). u Unscrew the hose connector (2) and the pipe connector (3) from the combination
u Open the shut-off valve between the compressor package and the air main. valve.
I Attentionl I After carrying out the oil change or oil cooler cleaning (with removal of u Unscrew the hex socket head screws (1) on the air cooler.
the oil cooler) run the compressor package up to operating tempera- u Remove and check the O-ring on the air cooler.
ture to ensure that the combination valve closes and that the oil cooler
is flooded with oil. u Close up the pipes and openings on the combination valve and air cooler.

Afterwards, repeat the procedures "Venting the Compressor Package" !

(chapter 9.10) and "Topping up the Oil" (chapter 9.12). i
I Attention! I Always use the same brand and type of oil when topping up (see label
I
on the oil separator tank).

If the type of oil is changed, drain the old oil completely and renew the '.'
oil filter.

Never use different types of oil.

9 - 37 9 -38
 Maintenance Maintenance

9.14 Oil Change (Oil Separator and Oil Cooler)

Carry out the oil change with the compressor at operating temperature.
6
Hot oil; beware of scalding!

The oil change interval is dependent on the degree 01 cooling air contamination and on the
ambient temperature.
II the compressor package is operated close to the maximum permissible ambient tem-
perature (see chapter 1.6), the oil must be changed more often, il necessary, the interval
should be halved.
See regular maintenance table (chapter 9.2) lor oil change interval.

6 I Attention! I Drain the oil out of the separator tank, cooler and the pipework com-
pletely. See chapter 9.14.4 for putting back into operation.
5 Hexagonal nut
6 Nlen screw 07 Shut down the compressor package under lull load (see chapter 8.4).

07 Unscrew the hex bolt (5). Switch off and lock out the main switch to prevent an accidental com-
pressor run.
The hex socket head bolts (6) are located behind two protective caps.

I Attention! I Before unscrewing the two hex socket head bolts (6) prop up the airl
2
11
oil cooler.
6
07 Remove the protective caps and unscrew the two hex socket head bolls (6).
07 Take out the airloil cooler. 3
Do not direct compressed air, water or steam jets at persons. These 4
jets represent contained energy and as such are dangerous to lifel

1
Clean the soiled cooler with water or steam jet in washing areas that
that are suitable for such cleaning work and provided with an oil sep-
arator! A F~
07 Clean the cooler cells with compressed air, water or steam jet.
LI U B~~~
07 Reassemble in the reverse order.
5
IAttentionl I Seat the 0 rings correctly in the compressed air inlet of the air cooler
during reassembly.

07 See chapter 9.12 for topping up the oil. 9

07 Open the shut -off valve between the compressor package and the air main. 7 I,
I
Carry out a trial run. 10
"

When the operating temperature is reached (see chapter 1.1) shut 8

down the compressor package (see chapter 8.4) and lock out the main
switch to prevent an accidental compressor run.

1 Shut - off valve 4 Filler plug 8 Screwed sealing plug

Carry out a visual check for leaks.
A shut (oil top - up) (oil cooler)
Bopen 5 Oil separator tank 9 Shut -off valve - oil drain
2 Pressure gauge 6 Plug - in nipple 10 Hose coupling
3 Hose coupling 7 Oil level mini -Imaximum 11 External pressurization

9 - 40 ,'
..
9 - 39 ,
II
r >,

Maintenance Maintenance

Before opening or removing pressurized components (pipes, hoses, 9.14.2 Adding oil
tanks, etc.) it is imperative that the compressor package is completely u Unscrew the oil filler plug (4) on the oil separator tank.
depressurized.

10" Venting the compressor package (see chapter 9.10). IAttention! I Always use the same brand and type of oil when topping up the oil.
(see label on the oil separator tank).

9.14.1 Draining the oil using external pressure source If a different type of oil is used drain the old oil completely and always
renew the oil filter.
10" Close the shut-off valve (1).
10" Insert the nipple (6) in the hose coupling (3) on the oil separator tank (5). Never mix different types of oil.
10" Apply external pressure source to the nipple until the pressure gauge (2) on the oil
u Top up the oil to the maximum mark.
separator tank (5) indicates approximately 3 bar.
For oil quantity see chapter 1.7.
10" Remove the nipple (6) from the hose coupling (3) on the oil separator tank (5).
10" Check the sealing ring on the oil filler plug (4) for damage and then screw in the oil
Draining the oil at the oil separator tank: filler plug.
10" Prepare a container to catch escaping oil.
9.14.3 Draining the oil using own compressed air
I Attention! I The container must be large enough to hold the total oil content of the
u Shut down the compressor package under full load (see chapter 8.4).
compressor package (see chapter 1.7).
Switch off and lock out the main switch to prevent an accidental com-
10" Hang the oil drain hose (10) in the canister and secure.
pressor run.
10" Slowly open the shut -off valve (9) (the remaining pressure in the oil circuit forces out
the oil). Close the shut -off valve (9) immediately when flir escapes. u Close the shut-off valve between the compressor package and the air main.

Before opening or removing pressurized components (pipes, hoses, The compressor oil circulation vents automatically.
tanks, etc.) it is imperative that the compressor package is completely u The pressure gauge on the oil separator tank must indicate zero bar.
depressurized.
10" Close the shut-off valve (1).
10" Venting the compressor package (see chapter 9.10).
Close all access doors and panels correctly before starting the com-
Drain the oil from the oil cooler: pressor package.
10" Prepare an oil container to catch the oil. u Start the compressor package (see chapter 8.4) and allow to run for approximately 30
10" Slowly unscrew the oil drain plug (1). The oil drains out under the force of gravity. seconds.
10" Screw the oil drain plug (1) back in tightly. ,\ )\ 10" Shut down the compressor package under full load (see chapter 8.4).

Dispose of the old oil according to environmental regulations. Switch off and lock out the main switch to prevent an accidental com-
pressor run.

u Check the actual pressure on the pressure gauge (2). Open the shut-off valve (1), let
the pressure on the pressure gauge (2) sink to approximately 3 bar and then close the
shut-off valve (1) again.
u Drain the oil from the oil separator tank and the oil cooler. Proceed as detailed in chap-
ter9.14.1.
u Open the shut-off valve (1).
u Top up with oil as described in chapter 9.14.2.

1 u Close all access doors and fit all cover panels.

1 Oil drain plug (oil cooler)

9 - 42
9 - 41
,
, I'
'

:I
!

Maintenance
Maintenance

9.14.4 Measures for putting back into operation

o:r Carry out measures detailed in "Pouring a small quantity of oil into the air inlet port"
see chapter 7.7.1.
3
o:r Carry out measures detailed in "Running the compressor package in idle"
see chapter 7.7.2.
2
o:r Carry out the measures detailed in "Venting the compressor package"
see chapter 9.10.
~-B

i ,
o:r Top up with oil, see chapter 9.14.2. 4
, '

o:r Open the shut-off valve between the compressor package and the air main. 5 .--9
I I
o:r Switch on the compressor package, see chapter 8.4, and allow to run until the operat- 7
ing temperature is reached, see chapter 1.1.
o:r Top up the oil again, see chapter 9.12. 1
13
Carry out a trial run. !)
When the operating temperature is reached (see chapter 1.1) shut 11
down the compressor package (see chapter 8.4) and lock out the main
switch to prevent an accidental compressor run. 12
Carry out a visual check for leaks. 5 10

9.15 Changing the Oil Separator Cartridge 1 Spring 6 a-Ring (dia.BOxB) 11 Dir1 trap screen filter
2 Hose coupling 7 Groove 12 Bbow fitting
The service life of the oil separator cartridge is strongly influenced by the degree of conta-
3 Pressure gauge B Oil separating car1ridge 13 Contro/line
mination of inlet air and on strict adherence to the recommended maintenance intervals of
the air and oil filters. 4 Hexagonal nut 9 a-Ring (dia.80x3,5)
5 Cover 10 Groove
We recommend that the oil separator cartridge is changed with the oil or when the relevant
service message is displayed on SIGMA CONTROL (see chapter 8.1).
Earthing the oil separator cartridge is by means of a spring, inset and
'o:r Shut down the compressor package under full load (see chapter 8.4), clamped in the separator cover (5).

Switch off and lock out the main switch to prevent an accidental com-
pressor run.
Before opening or removing pressurized components (pipes, hoses,
tanks, etc.) it is imperative that the compressor package is completely
depressurized.
o:r Venting the compressor package (see chapter 9.10).
Care must be taken when changing the separator cartridge, not to
damage this spring as earthing can only be ensured when it is in per-
fect condition.
o:r Unscrew the hexagonal bolts (4) and remove the cover plate (5).
o:r Take out the old oil separator cartridge (8) with the 0 ring (6) and 0 ring (9) and dis-
pose of according to environmental regulations.
o:r Clean the sealing surfaces of the oil separator tank.

IAttention! I The oil separating cartridge is disposable and cannot be cleaned.

o:r Insert the new 0 ring (9) into the groove (10) in the oil separator tank.
o:r Insert the new oil separator cartridge (8) and then insert the new 0 ring (6) into the
groove (7).
o:r Fit the cover plate (5) and tighten down with the hexagonal bolts (4).
o:r Unscrew the union nut of the elbow fitting (12) and pull out the control air pipe (13).
o:r Unscrew and remove the elbow fitting (12) from the oil separator tank together with
the dirt trap screen filter (11).
o:r Replace the old dirt trap screen filter with a new one.

9 - 43 9 - 44
 Maintenance Spare Parts and After Sales Service

117 Wrap teflon tape around the outside thread of the elbow fitting (12) and screw back 10 Spare Parts and After Sales Service
into the oil separator tank.
117 Insert the control air pipe (13) into the elbow fitting (12) and tighten up the union nut.
117 Open the shut-off valve between the compressor package and the air main. 10.1 Service parts and expendable parts
Carry out a trial run. No. off Order No.
Description
When the operating temperature is reached (see chapter 1.1) shut Oil filter 1 6.1876.1
down the compressor package (see chapter 8.4) and lock out the main (Operating temperature <gaC) <

switch to prevent an accidental compressor run. Oil filter 6.1876.10020

(Operating temperature ~9OC
1
e.g. South-East-Asia)
Carry out a visual check for leaks.
Air filter cartridge 1 6.0215.0

Filter mat 1 6.1891.0

Oil separator cartridge

Complete set 1 6.2024.0

Comprising:
Separating cartridge
o Ring
1
2
,i
.1
Dirt trap screen filter 1 ,,[
Hose pipe from the minimum
pressure check valve to the
1 8.1190.1
II,I
air/oil cooler I

I
Hose pipe from the air/oil 1 8.1181.0
cooler to the compressor air
end

See chapter 1.3 for details of the V-belt set.

KAESER KOMPRESSOREN GmbH

I~.~lia.~~d
D-'36~1O Coburg, Postfach 2143
L} ) Germany, Tel.: (09561) 640-0
Fm(.: 109561) 640-130
(:
IModel I I
I Port No. I I
I Serial No. I I
I Year I I
IRated power I kWI
IRated motor speed I mln11

I rPermlss. gouge working press. I I barl

Important for all queries:

117 Enter the data on your compressor's nameplate in the nameplate shown above.
Always quote the data on the nameplate when making a query or ordering spares.

IAttention! I Always order original spares from the compressor manufacturer to

avoid lowering the quality of your compressor package.

9 - 45 10 --46
l'---

''/\
~
""
~ J.
Spare Parts and After Sales Service Appendix
<._
",-

10.2 Service and Maintenance Agreement 11 Appendix

We recommend that you take out a service and maintenance agreement with an author-
ized KAESER service agency, This is your best guarantee of reliable air supplies.
11.1 Electrical Diagram

11 -A8
10 - 47
 ~--

- - -- ....
- .-.-.. ~

1 2 I 1 4 5 6 I J e

Electrical diagrams
Compressor SM 11
440-460-480V SO/60Hz

Manufacturer: Kaeser Kompressoren GmbH

Postfach 2143
96410 Coburg

,
b
,
Datum 29.05.2000
Bearb. Oberender
Gepr. Fischer
E
KAESER
KOMPRESSOREN
Cover page
Compressor SM 11
.
A Anderung
,=
Oatum Name
"". Ersah durch, Ersah fUr: Ursprung, AMS010S1.00 Sigma Control T DSM11-01021.00 Blatt 1
Bl.
~,
',.~"
.?J iSff ...
-.
:5--
~

- , , ~

lfd. Nr. Benermung Zeicnnungsnummer (Kunde) Zeichnungsnummer (Hers~eller) Blatt Ani agenkenn zeic hen
N,. Name Dra .... ing No. (customer) Drawing No. (manufacturer! Page Unit designation

1 (over page DSM11-01021.00 1

2 List of contents ZSM'1-01021.00 1
1 Block diagram USM1'-01Q21.00 1
4 (irtuit diagram Power switching SSM11-01021.00 1
5 Circuit diagram (ontrol voltage tapping SSM11-01021.OC 2

,
6 Circuit diagram
Circuit diagram
Power supply unit
motne:r board/Inputs
SSMll-01021.00
SSM11-01021.00
l
4
e Circuit diagram mother board/Inputs SSM11-01021.00 5
9
10
Circuit diagram
CirCuit diagram
mothe:r board/Inputs
mother beard/Outputs
SSM1101021.0Q
SSMll-0l021.00 ,
6

11 Circuit diagram mother bDard/Outputs SSM11-01021.00 8

12
13
Electrical equipment identification
Equipment parts list Control Cl;lbinet
SSM11-01021.00
GSM1101021.00 ,
9

14 Terminal schedule Terminal strip -X11 KSM11-01021.0Q 1

'5 Component l<!yout Mounting plate ASMll-0l021.00 1
"

Compressor SM 11

.__ ___
.~~ c_===~=============.,.",."=~""""" ........"""",, ........"""""'!
 - ------'-lj

1 1 4
~

r--Power
- ---switching
-- - --- --- --- --- --- -- - ---- ,- --EI ---
A-interface
-- - -- - ----24V--to sensors
--- --and- outputs
-- - - ---

~i ~
PE 0---- -----;
:~ Adapter 1
[QGJ
/

lX32
lliIl ~ @DJ ~ ~
~>:'3_'_ _ _ _ 2X3S _E~_2X_4_'_~x~

GPGfJ l T )
L___ --t----t~-----------
Power uni~
W8\ W8) W81

2 10 4 1\
r-- Sigma Control
4
:----------;x-;------- ---I
I o-V"- i '
, >' mother board
EMERGENCY STOF 1-
~1
activation
Compressor motor L ____________
1 lX2
._. ___ .--l[
WB7

7 1\
--- -- - -- -- -- - -- - --- ----------
W19
activation
(ompressor motor
,1
L_. _____ _~___ _ ___ _ _ _ _ _ __ _ _ _ __ __ _ _ _ USl:lr's connection
--- --- ---- -- --- -- -. --- -- -___________________ -.J
M
3-
Compressor motor
l
~
b
\ IDitom 129.05.2000
8earb. Oberender KAESER Block diagram

a I
C Anderung
I
Datum
I IGe~r. I
Name Norm
FisCber
Er5at~ dun:h, Ersatz fur,
KOMPRESSOREN
Ursprung, AM5010S1,QO
Compressor SM 11
USM11-01021.00 ~
rs ~~
. :~4~
""" v ,'..$
"~-
\J

_/ 5.
1 , ) 4 \ 6 I 7 B

L1 12.1
L2 12.1
Ll

----------------,--
I _
1- ~--.-----------------------------------------~

I -X11 ~PE
H07V_K

I I k-<-- V 2.5mm' black

I I
I H01V-K

I 2,Smm' black - - -
I'- I'--j'-

-X11 5 :; i~~ -K1M 1 )

,- ,_.
\
I
I -K2M
, -,, ,
1
-
) \ -K3M [11
, ,
--

1 1 1
I
I
I
I
I I
1 1
/B.3
4
, i /8,5 /8_4 . -'
4

k----L----
H07V-K
2,5mm' black
I I I I ."-'
fvH--\ :
I I I I -F2
6-B,5A
1

,
)

. ~~
\ -f'91
1
~ .
,1 , 4 6 ]698]
,1 ,
,
1
1 ~ i
1 1

, ,,
Main switch, 1 NYSl YO-J
fuse supplied 1 1 1
1 1
h1,Smm'
i.
by user
,
1O.m U, 1 PE
i'-
V,
1 1 1
,,, W1
M \u,
1
, V1
u-,-, 3-
1 1 1
, jW,
1 1 1
1 1 1 , ,
-M1
1 1 1
, 7,5 kW
1 1
1
1
1 , , AHENTiON !!1
Control transformer connections for
Lll2l3PE
440-460-480V/3/PE/50/60Hz 41,.0V: 440 and 0
See service manual for 460V: 1,.40 and .ZOV
supply cable cross-section 480V: 500 and -lOV

Fumtlon: Compressor morer I

Group of fun,tlons.: Main power supply I Power switching 1
, Datum 29.05.2000
KAESER Circuit diagram
b Searb. Oberen~er Compressor SM 11
KQMPRESSQREN
o Anderung O~tum Harne
Gepr fisther
Norm Er5at~ dUTch, Er~at: fur, Uu~rung: Ar1S010$1.00 Power switching I SSM11-01021.00 .. ~BI.
 I 4 6

Ll -X11_, -Xll.,
LO'. /~
;Q r-
-Xll ,

-53 ~'
Ho7v-K
2.5mm" black ____
o-.i.. ----IS 2
-FO" EMERGENCY STOP 1Z 1 .
-00
f
ffi~
O,ZS-O,I.A ~: -
. ,
'

I t I
lA"

-S10
Door safety interlock switch
left
h
f-- --t' 12
4"/5.3

~ -Xll !,

-Xll AJ

-T1===~~~
20Q~S10I2x11SV
ro---mI ro---mI I
160VA I ~ l...----...J L02
'0.
.- 1

ATTENTION !!!
nov
[Imtrol transformer connedions tor connedion
s,b.c,
1.40V: 440 and 0
-Xll~
10VA
460V: 440 and .. lOV
48DV; 500 and -lOY

-xll1:E
L -_ _ _ _ _ _ _ _ _ _ _ _ ~
,
-X11,\, N01 /3.1
Secondary side is earthed.
If the shorting link
is removed, insul .. tion
monitoring must be
installed
EN 60204-1

Control cabinet wiring:

AU non-designated conductors
230V AC: lmm' red HOSV_K
24V DC: O.15mm' blue HOSV_K

F~lIdicn: 230V/t-/S0/60Hz EMERGENCY STOP Door safety interlock switch

Grau~ at tunctlons, Control voltage tapping Safety chain
Datum Z9.0S.Z000 Circuit diagram
Bearb. Oberender KAESER Compressor 5M 11
Gepr. Fischer KOMPRESSOREN
o I Ande~ I O;;tum

"
I Name I Norm Ersatz durch, Er$~tz f.Qr, Ursprung, AMS010StOO Con~rol vol~age ~appiug
1 SSMll-01021.00
.,
B!<Jtt 2
--Bl.
""~
..-.-~ '''''.-~./ ,df r:::;
j
1 , J I 4 5 6 I 1 ,
24V DC lL .. IS.l
24V DC 2L .. IS.l
I2.B LOi

-2X20 )9
-2X020 9

-Gl '.
-A 10.0 0
b- 81 188D
I;'::
0
230V- 0
l M -Xll PE 0
24V= 0
N
1,3A
short tiHuit prQ~f
~
1 0

RS 485
ODD Sigma (ontrol
-lX8 RS 232 -lX7
D
Profibus
I .u;o;;I;;U;;a. I I I Itt I I I 1AUMX;O:;t. I
~ ~cl. O-Sub
-lX9
9 pol. O-Sub
-AiD,' 14.1 }

-Xll
"'

!Z.8 N01 NG1 1a.1

-2X020 too

."'']" 1M 14.1
2M 11.1

Fun,tlcn: 24V DC
Group of f~netlons, (ontrol vOltage tapping T Adapter 1
, Datu.. 29.05 ... 000 Circuit diagram
B~arb. Oberender
KAESER Compressor SM 11
,b KOMPRESSOREN
o Anderung Datum N~l1Ie
Gepr. fischer
Norm Er5atz durch, Ersatz fun Ursprung, AMS010StDO Power supply uni~ I SSMll-0l021.00 ~BI.
 -.-_._-_.- -------.
....----. -~J

, I l I 4 5 ,
<t
:t~
~

-81 Airend discharge temperature

~
Air main pressure -811
J
PT laO H

12 11 PE

ct::1J ct -----------t)
-----------
-2X041A,' A,' -2X043 AI' -2X043 At
-2X41 , , -2X43 , -2X43 , t

-2Xl A" -2Xl "" -2Xl A" -2Xl "''' -2Xl ",10 -2Xl A" -2Xl All -2Xl "'" -2Xl ",24 -2Xl "'" -2Xl ""5 -2Xll,

~~~11;~~~~; l'_~~011 ~O~2_X~11 ~~2_:_'~:: 1'_'-': =-:""'1=-:""'_1;' :'''' I; _-'''' I;; _

-''''I' I
-Al0.l \
I-lxo~" 1, I" -1"
1 ___
-1X1 -21
~
-9
L -20
____ GNO' ____ ...!!! ___
t t t -22
t,
_.2J....2_ ___ ~D1 __ _~D_l
10
-'0 ..... '1
____
..... 23
II
..... 12 ..... 24 -13 ..... 25
A~
AI 1__ _.:.......E.NE_'_ _ _ _ 4_________________
..... 7 )
t !1~
..L

AI 1 AI 2 AI 3 AI 4

/3.8 -AlO.' } m,th" bw' _Al0.2/ S.2

AI , Air mdin pressure AI 3 Airenc discharge temperature
/ - 'OP"" All AI4

/3.8 1M '" 1M /7.1

I Fu~tlion,
IGroup of fun~tion~, Pressure control
Datul Circuit diagram
Searb. KAESER
---- _.-
. [omoresc:.nr ,M 11
I <; <;M"_0 1021.0 0

<t~ <;;;....,. '--.~ tJ

~

4 _J , I
/6.1
/3.B .1!:..:.
I!::.!.../6.1
/3.B 1..!:.:

-2X3! 5 -2X32
-2X032 ~l
-2X31 .'
-2X03 Ys -2X031r

-F2 195 -82 I'

12.5--~~~-7.'
-510 11
/2.1"4----- /1.3 -l1; IEJ--
l " I" 196 0,7-1,2bar !2

-2X03 A' -2X031,1" -2X020 A, -2X032 A,

-
2X3
1' - 1'
2X31
-2X20 l' -2X32l'

____~'~~ _____-2:~~_____-~: ~---- "1--- "ll

-2Xl , -2Xl , -2Xl l -2Xl 4 -2Xl "'5 -2Xl ""

~~l
-Al0.2 ' \ -1X1 -, -2 -3 -4 -5 -6 \
1_ _ ~ _ _ _ _ _ _ _ ~ ________or~ _ _ _ _ _ _ _DI: _ _ _ _ _ _ _D~5_- _ _ _ _ _ ~_'_,
10.0 10.1 10.2 1003 10.4 10.5
mother board -Al0.3 /6.2
Inputs I 0.0 EMERGENCY STOP pushbutton I 0.3 Direction of rotation
I 0.1 Door safety interlock switch I 0.4
I 0.2 Compressor motor overload protection I 0.5

function:
Grou~ of functions, Alarm/maintenance indications
Circuit diagram
Datu..
S~~rb.
29.D5.2000
Oberender
KAESER Compressor SM 11
KOMPRESSOREN Blatt 5
o Ander~nq Datum Name
Gepr.
Norm
Finher
Ersatz dureh: Er5atz lur: Ur$~rung, AMS010S1.CO mother board/Inputs 1 SSM11-01021.00 BI.
 -~,'

r
4 6

/S.B ll~ -Xl1 P1 -X11 P1 X11

a a -X11 f2

II"
/S.6 2L 2l .. 17.1
-
-2X35 12

-K1M
1'-' \
14

1::
-X11 " -X11 12 -X11 13 -X11 14 -X11 15

-2X020 A2 -2X020 All -2X020 A4 p-2X020 As -2X020 AI' -2X020 AI'

-2X20 2

-2X1 1 14
-2X20 l

-2X1 15
-2X20 4

-2X1 1 "
-2X35

-2X1
1 -2X20 5 -2X20 ,

" -2X1 1B
-2X20 ,

-2X1 19

~~~11'~ ____ ~~~1!~ _____ -~:_" _ _ _ _ _-:X01 ~ ____ ~2X01y; _____-2XO~l'; _I

-Al0.3 \
1-1xo~t
-lX1D~;4
-1"D~~5 "
D~~6 ,
"
D~~7
~
O~~B
t-
D~r.;1;9;--ri--'
1______ - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - ,
10.6 10.7 11.0 11.1 11.2 11.3

15.1 -A1D.3 mother board

Inputs
-A1D.4 11.2 }
I 0.6 Answerback signal Mains (on tact or 11.1
I 0.1 load/idling exl'ernal I 1.2 ALARM external .u

I to Remote ON/OFF I 1.3 Maintenance e~tl!rnal

u default setting Remove the link when an <Jtarm

can be changed serlsor i5 connected.
through the user interface

Funetiol'l'.
Group Df funtlions: ~ indications

KAESER I Circuit diagram

Compressor SM 11
TBiatT6
.'~
I Ersat
.~
mother board/Inputs
~"9r
I SSM11-01021,00
~
'C., ,
:.;;) ;.;
~
-"
I~"-~'

----',

4 6

.... default seHing

can be changed
/5.8.l!:! through the user interface

-A10,4 ,'------------------------------------------------------------------------------------------,

mother board o 0.6 Control valve

Power supply unit o 0.7 TImer ..

/6.1 -Al0.4 -A1O.5 1'.2 )

o 0.6 o 0.7
~-lrn----_m4---------~O~-----------------~.-,-

I -1X311 14 12 13

c~l---J~------J~-----------f~
-2X03 ),1 -2X03 ),4 -2X03 ),2 -2X03 ),l
-2X3 1, -2X3 14 -2X3 12 -2X3 13

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-2X37
-2X037 "'1

-X11 16
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-2X37 2
r
-X11 HI

Furn:tion: Inlet/ Venting Condensate drain. User's tonnedion

GNlup of fundicns: mother boarl:l
D~tum 29.Q5.2000
KAESER Circuit diagram L
Burb. Oberender
KOMPRESSOREN Compressor SM 11
1 ~
6epr. Fis(h~r

o Anderunq Carum Name lIIorm Ersatz durch: EtS~!'l fUr: Ur~prung, AHS0105tcO mother board/Outputs SSM11-01021.00 SI,

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, Oatum 29.~5.2000 (ompotlent l<:iyout I"

b B@~rb, Ob~reMer
KAESER Compressor SM 11
KOMPRESSOREN
I A~deMJng I ~
Gapr. fis,her
O~tum Name Norm Ers~tz ~urch, E,sat~ fur: Ursprung: AMS010SI.OO Mounting plate ASM11-01021.00 Bl. '
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-A 10.1...-A 10.5 mother board, Inputs/Outputs
-FO -F2

}
Cut-out Control secondary Compressor motor overload protection
Shutdown function
-Gl Power unit -82 Direction of rotation pressure switch
and
-K1M Mains contactor -Bll Temperature probe
Indicating function
-K2M Oelta contactor Airend discharge temperature
-K3M Star contactor
-Ml Compressor motor
-81 Pressure transducer, } Indicating function
-00 Overload protection switch,
Air main pressure
(ontro! transformer
-53 EMERGENCY STOP pushbutton
-510 Door safety interlock switch

-T1 (antral transformer

-Xll Terminal strip, Control
-lX1...-1X3 connector strip Sigma Control, mother board
-lX7 ... -1X9 connector strip Sigma Control, interface
-lXOl..-1X03 Connector plug, Sigma [ontrol
-2Xl. -2X3.-2X20 connector strip Adapter 1, internal
-2X01, -2X03,-2X020 Connector plug Adapter 1, internal
-2X31...-2X43 connector strip Adapter 1, external
-2X031...-2X043 Connector plug Adapter 1. external
-Yl Control valve

Datum 29.05.2000
Searb. Oberender KAESER Ele[trical equipment identification
r,
EIAnderung Gepr Fischer KOMPRESSOREN Compressor SM 11
Datum Name NDrm I Ersatz durch, I Ersatz fUr: Ursprung, AMS01051.CO
1 55M11-01021.00 Blatt 9
-- Bt.
 Oestination Oestination
(able identification Terminal strip (able identification
external internal

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i
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3
3.

Serial number of the unit:

total 31 Terminals

X
-M1
supply
P' PE
PE
11.4
11.2
-M1
ountin9 plat~
P'

X supply U1 11.2 -K2M 1 Date Description of work Service hours Signature

I
, X
X
supply
supply
V1
W1
1
11.2
11.2
12.4
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-K2M
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3
5
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12.5 -S3 12 X
X
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11

3
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: 11 P1 .... 16.6
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