Manual de Servicio CSD 125T

Operator Manual
Rotary screw compressor
CSD 100/125 T
901726 08 USE
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/SCSDX 2.18 en Z1 SBA-SCHRAUBEN-T-SC
/KKW/SSC 2.08 Z1
20180111 113017
Contents
1 Regarding this Document

1.1 Using this document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and labels .......................................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Potential damage warnings ................................................................................ 2
1.4.3 Other alerts and their symbols ............................................................................ 2
2 Technical Data
2.1 Nameplate ........................................................................................................................ 4
2.2 Options ............................................................................................................................. 4
2.3 Weight .............................................................................................................................. 5
2.4 Temperature ..................................................................................................................... 5
2.5 Ambient conditions ........................................................................................................... 6
2.6 Ventilation ........................................................................................................................ 6
2.7 Pressure ........................................................................................................................... 6
2.8 Free air delivery (FAD) ..................................................................................................... 7
2.9 Cooling Oil Recommendation .......................................................................................... 7
2.9.1 Basic Information ................................................................................................ 7
2.9.2 KAESER Lubricants ............................................................................................ 7
2.10 Cooling oil charge ............................................................................................................ 8
2.11 Motors and power ............................................................................................................ 9
2.11.1 Compressor drive motor ..................................................................................... 9
2.11.2 Fan motor ........................................................................................................... 9
2.11.3 Fan motor ........................................................................................................... 10
2.12 Noise emission ................................................................................................................. 10
2.13 Power Supply ................................................................................................................... 10
2.14 Power supply specifications ............................................................................................. 11
2.15 Water-cooling ................................................................................................................... 12
2.15.1 Water cooling (plate-type heat exchanger) ......................................................... 13
2.15.2 Water cooling (Bundled pipe heat exchanger) ................................................... 15
2.16 Heat recovery ................................................................................................................... 17
2.17 Refrigerated dryer ............................................................................................................ 20
3 Safety and Responsibility
3.1 Basic instructions ............................................................................................................. 21
3.2 Specified use .................................................................................................................... 21
3.3 Improper use .................................................................................................................... 21
3.4 User's Responsibilities ..................................................................................................... 21
3.4.1 Observe statutory and universally accepted regulations .................................... 21
3.4.2 Qualified personnel ............................................................................................. 22
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 22
3.5 Dangers ............................................................................................................................ 22
3.5.1 Safely dealing with sources of danger ................................................................ 23
3.5.2 Safe machine operation ...................................................................................... 25
3.5.3 Organizational Measures .................................................................................... 27
3.5.4 Danger Areas ...................................................................................................... 27
3.6 Safety devices .................................................................................................................. 27
3.7 Working life of safety functions ........................................................................................ 28
3.8 Safety signs ...................................................................................................................... 28
3.9 Emergency situations ....................................................................................................... 31
3.9.1 Correct fire fighting ............................................................................................. 31
3.9.2 Treating injuries from handling cooling oil .......................................................... 31
3.9.3 Injury from Handling Refrigerant ......................................................................... 32
Operator Manual Rotary screw compressor

901726 08 USE CSD 100/125 T i
Contents
3.10 Warranty ........................................................................................................................... 33

3.11 Environmental protection ................................................................................................. 33
4 Design and Function
4.1 Enclosure ......................................................................................................................... 34
4.2 Machine function .............................................................................................................. 34
4.2.1 Refrigerated dryer ............................................................................................... 36
4.2.2 Safety devices .................................................................................................... 36
4.2.3 Floating relay contacts ........................................................................................ 36
4.3 Operating panel SIGMA CONTROL 2 ............................................................................. 37
4.4 Operating modes and control modes ............................................................................... 39
4.4.1 Operating modes ................................................................................................ 39
4.4.2 Control modes .................................................................................................... 40
4.5 Refrigerated Dryer Control Modes ................................................................................... 42
4.6 Options ............................................................................................................................. 42
4.6.1 Controller SIGMA CONTROL 2: Connection to control technology .................... 42
4.6.2 Machine mountings ............................................................................................. 42
4.6.3 Water cooling ...................................................................................................... 43
4.6.4 Cooling air filter mat ............................................................................................ 44
4.6.5 Heat recovery ..................................................................................................... 44
5 Installation and Operating Conditions
5.1 Ensuring safety ................................................................................................................ 46
5.2 Installation conditions ....................................................................................................... 46
5.2.1 Determining location and clearances .................................................................. 46
5.2.2 Ensuring adequate ventilation ............................................................................ 47
5.2.3 Exhaust duct design ........................................................................................... 48
5.3 Operating the machine in a compressed air network ....................................................... 48
6 Installation
6.1 Ensuring safety ................................................................................................................ 49
6.2 Reporting Transport Damage ........................................................................................... 50
6.3 Connecting the machine with the compressed air network .............................................. 50
6.4 Connecting the condensate drain .................................................................................... 50
6.5 Connecting the external pressure transducer .................................................................. 52
6.6 Refrigerated dryer: Connecting the transformer according to the power supply. ............. 53
6.7 Connecting the machine with the power supply ............................................................... 53
6.8 Options ............................................................................................................................. 54
6.8.1 Anchoring the machine ....................................................................................... 54
6.8.2 Connecting the water cooling ............................................................................. 54
6.8.3 Connecting the heat recovery system ................................................................ 55
7 Initial Start-up
7.1 Ensuring safety ................................................................................................................ 57
7.2 Instructions to be observed before commissioning or re-commissioning ......................... 58
7.3 Checking installation and operating conditions ................................................................ 58
7.4 Setting the overload protection relay ................................................................................ 59
7.5 Setting the motor overload protection relay ..................................................................... 59
7.6 Filling cooling oil into the airend ....................................................................................... 59
7.7 Activating and deactivating the MODULATING control .................................................... 61
7.8 Starting the machine for the first time .............................................................................. 61
7.9 Setting the setpoint pressure ........................................................................................... 62
7.10 Setting the display language ............................................................................................ 62
8 Operation
8.1 Switching on and off ......................................................................................................... 64
8.1.1 Switching on ....................................................................................................... 64

ii CSD 100/125 T 901726 08 USE
Contents
8.1.2 Switching off ....................................................................................................... 64

8.2 Switching off in an emergency and switching on again .................................................... 65
8.3 Switching on and off from a remote control center ........................................................... 65
8.4 Using the timer for switching on and off ........................................................................... 66
8.5 Interpreting operation messages ...................................................................................... 67
8.6 Acknowledging alarm and warning messages ................................................................. 67
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 69
9.2 Other faults ....................................................................................................................... 69
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 71
10.2 Following the maintenance plan ....................................................................................... 72
10.2.1 Logging maintenance work ................................................................................. 72
10.2.2 Resetting maintenance interval counters ............................................................ 72
10.2.3 Regular maintenance tasks ................................................................................ 72
10.2.4 Cooling oil changing interval ............................................................................... 74
10.2.5 Regular service tasks ......................................................................................... 74
10.3 Control cabinet: Clean or renew the filter mat .................................................................. 75
10.4 Cooler maintenance ......................................................................................................... 75
10.5 Water-cooling Maintenance ............................................................................................. 76
10.6 Cleaning or Renewing the Cooling Air Filter Mat ............................................................. 77
10.7 Maintaining the heat recovery system .............................................................................. 78
10.8 Air filter maintenance ....................................................................................................... 78
10.8.1 Cleaning the pre-filter ......................................................................................... 79
10.8.2 Cleaning or replacing the pre-filter and air filter cartridge ................................... 79
10.9 Motor maintenance .......................................................................................................... 80
10.10 Checking the Coupling ..................................................................................................... 81
10.11 Testing the safety relief valve ........................................................................................... 82
10.12 Checking the overheating safety shutdown function ........................................................ 83
10.13 Testing the EMERGENCY STOP push button ................................................................. 84
10.14 Checking the cooling oil level ........................................................................................... 84
10.15 Venting the machine (de-pressurizing) ............................................................................ 85
10.16 Replenishing the cooling oil ............................................................................................. 87
10.16.1 Venting the machine (de-pressurizing) ............................................................... 87
10.16.2 Topping off with cooling oil and trial run ............................................................. 88
10.17 Changing the cooling oil ................................................................................................... 89
10.18 Changing the oil filter element .......................................................................................... 94
10.19 Changing the oil separator cartridge ................................................................................ 95
10.20 Cleaning the refrigerant condenser .................................................................................. 97
10.21 Maintaining the condensate drain .................................................................................... 97
10.21.1 Condensate drain check ..................................................................................... 97
10.21.2 Changing the service unit ................................................................................... 98
10.22 Documenting maintenance and service work .................................................................. 102
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 103
11.2 Ordering spare parts and operating fluids/materials ........................................................ 103
11.3 KAESER AIR SERVICE ................................................................................................... 103
11.4 Replacement parts for service and repair ........................................................................ 104
12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 111
12.1.1 Temporary decommissioning .............................................................................. 111
12.1.2 Long-term decommissioning ............................................................................... 111

901726 08 USE CSD 100/125 T iii
Contents
12.2 Packing ............................................................................................................................ 112

12.3 Storage ............................................................................................................................. 112
12.4 Transport .......................................................................................................................... 112
12.4.1 Safety .................................................................................................................. 112
12.4.2 Transport with a forklift truck ............................................................................... 113
12.4.3 Transport with a crane ........................................................................................ 113
12.5 Disposal ........................................................................................................................... 115
12.5.1 Battery disposal .................................................................................................. 115
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 116
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ........... 122
13.3 Dimensional drawing ........................................................................................................ 128
13.4 Electrical Diagram ............................................................................................................ 132

iv CSD 100/125 T 901726 08 USE
List of Illustrations
Fig. 1 Three-phase (wye system); 4 wire; center point solidly grounded ............................................. 11
Fig. 2 Three-phase (wye system); 3 wire; center point solidly grounded ............................................. 11
Fig. 3 Location of safety signs .............................................................................................................. 29
Fig. 4 Enclosure overview .................................................................................................................... 34
Fig. 5 Machine overview ....................................................................................................................... 35
Fig. 6 Refrigerated dryer ...................................................................................................................... 36
Fig. 7 Keys - overview .......................................................................................................................... 37
Fig. 8 Indicators – overview .................................................................................................................. 38
Fig. 9 RFID sensor field ........................................................................................................................ 39
Fig. 10 Machine mountings .................................................................................................................... 43
Fig. 11 Water-cooling (Option K2) .......................................................................................................... 43
Fig. 12 Water cooling (Option K9) .......................................................................................................... 43
Fig. 13 Cooling air filter mat (option K3) ................................................................................................. 44
Fig. 14 Function of the heat recovery ..................................................................................................... 45
Fig. 15 Recommended machine placement and dimensions [in.] .......................................................... 47
Fig. 16 Compressed air piping ............................................................................................................... 50
Fig. 17 Connecting the condensate drain ............................................................................................... 52
Fig. 18 Connecting the water cooling ..................................................................................................... 54
Fig. 19 Connecting the heat recovery system ........................................................................................ 55
Fig. 20 Inlet valve filling port ................................................................................................................... 60
Fig. 21 Coupling ..................................................................................................................................... 60
Fig. 22 MODULATING control: Setting the shut-off valve ...................................................................... 61
Fig. 23 Switching on and off ................................................................................................................... 64
Fig. 24 Switching off in an emergency ................................................................................................... 65
Fig. 25 Switching on and off from a remote control center ..................................................................... 66
Fig. 26 Using the timer for switching on and off ..................................................................................... 67
Fig. 27 Acknowledging messages .......................................................................................................... 68
Fig. 28 Switching cabinet ventilation ...................................................................................................... 75
Fig. 29 Clean cooler/radiator .................................................................................................................. 76
Fig. 30 Cooling air filter mat ................................................................................................................... 77
Fig. 31 Cleaning the pre-filter ................................................................................................................. 79
Fig. 32 Air filter maintenance .................................................................................................................. 80
Fig. 33 Motor maintenance ..................................................................................................................... 81
Fig. 34 Checking the coupling ................................................................................................................ 82
Fig. 35 Testing the EMERGENCY STOP push button ........................................................................... 84
Fig. 36 Checking the cooling oil level ..................................................................................................... 85
Fig. 37 Venting the machine ................................................................................................................... 86
Fig. 38 Replenishing the cooling oil ........................................................................................................ 87
Fig. 39 Changing the cooling oil, oil separator tank ............................................................................... 90
Fig. 40 Changing the cooling oil, oil cooler ............................................................................................. 91
Fig. 41 Changing the cooling oil, airend ................................................................................................. 92
Fig. 42 Changing the cooling oil, heat recovery system ......................................................................... 93
Fig. 43 Changing the oil filter element .................................................................................................... 94
Fig. 44 Changing the oil separator cartridge .......................................................................................... 96
Fig. 45 Refrigeration dryer ...................................................................................................................... 97
Fig. 46 Condensate drain check ............................................................................................................. 98
Fig. 47 Changing the service unit ........................................................................................................... 99
Fig. 48 Changing the service unit ........................................................................................................... 100
Fig. 49 Transport with a forklift truck ...................................................................................................... 113
Fig. 50 Transport with a crane ................................................................................................................ 114
Fig. 51 Battery disposal .......................................................................................................................... 115

901726 08 USE CSD 100/125 T v
List of Illustrations

vi CSD 100/125 T 901726 08 USE
List of Tables
Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Tab. 2 Danger levels and their definition (damage to property) ............................................................ 2
Tab. 3 Nameplate .................................................................................................................................. 4
Tab. 4 Options ....................................................................................................................................... 4
Tab. 5 Machine weight .......................................................................................................................... 5
Tab. 6 Temperature ............................................................................................................................... 5
Tab. 7 Ambient conditions ..................................................................................................................... 6
Tab. 8 Ventilation ................................................................................................................................... 6
Tab. 9 Safety relief valve activating pressure ....................................................................................... 6
Tab. 10 Free air delivery .......................................................................................................................... 7
Tab. 11 Cooling oil charge (Option K1) ................................................................................................... 8
Tab. 14 Cooling oil charge (Option W2) .................................................................................................. 9
Tab. 15 Cooling oil charge (Option W3) .................................................................................................. 9
Tab. 16 Compressor drive motor ............................................................................................................. 9
Tab. 17 Fan motor (Option K1) ................................................................................................................ 9
Tab. 18 Fan motor (Option K2/K9) .......................................................................................................... 10
Tab. 19 Noise emission ........................................................................................................................... 10
Tab. 20 Power supply details (230V / 3 / 60Hz) ...................................................................................... 11
Tab. 23 Power supply details (575V / 3 / 60Hz) ..................................................................................... 12
Tab. 24 Water cooling K2: Individual design data ................................................................................... 13
Tab. 25 Component specification (Option K2) ......................................................................................... 14
Tab. 26 Cooling water quality (Plate-type heat exchanger) ..................................................................... 14
Tab. 27 Cooling water temperature (ΔT= 20 °F) ..................................................................................... 15
Tab. 28 Cooling water temperature (ΔT= 50 °F) ..................................................................................... 15
Tab. 29 Water cooling K9: Individual design data ................................................................................... 15
Tab. 30 Component specification (Option K9) ......................................................................................... 16
Tab. 31 Cooling water quality (Bundled-pipe heat exchanger) ................................................................ 16
Tab. 32 Cooling water temperature (ΔT=20 °F) ...................................................................................... 17
Tab. 33 Cooling water temperature (ΔT=50 °F) ...................................................................................... 17
Tab. 34 Heat recovery: Individual design data ........................................................................................ 18
Tab. 35 Specification: Heat exchanger (Option W2/W3) ......................................................................... 18
Tab. 36 Quality of the heat receiving medium ......................................................................................... 19
Tab. 37 Heat capacity (Option W2/W3) ................................................................................................... 19
Tab. 38 Flow rate / pressure drop (option W2) ........................................................................................ 19
Tab. 39 Flow rate / pressure drop (option W3) ........................................................................................ 19
Tab. 40 Refrigerated dryer: Compressed air system ............................................................................... 20
Tab. 41 Refrigerated dryer: Refrigerant circuit ........................................................................................ 20
Tab. 42 Danger Areas ............................................................................................................................. 27
Tab. 43 Safety signs ................................................................................................................................ 29
Tab. 44 Keys ........................................................................................................................................... 37
Tab. 45 Indicators .................................................................................................................................... 38
Tab. 46 RFID sensor field ........................................................................................................................ 39
Tab. 47 Energy-saving control modes ..................................................................................................... 41
Tab. 48 Refrigerated dryer control modes ............................................................................................... 42
Tab. 49 Components ............................................................................................................................... 42
Tab. 50 Condensate line ......................................................................................................................... 51
Tab. 51 Condensate collecting line ......................................................................................................... 51
Tab. 52 Condensate collecting line: Line diameter .................................................................................. 51
Tab. 53 Re-commissioning after storage ................................................................................................. 58
Tab. 54 Installation conditions checklist .................................................................................................. 58

901726 08 USE CSD 100/125 T vii
List of Tables
Tab. 55 MODULATING control: Setting the shut-off valve ...................................................................... 61

Tab. 56 Machine identification ................................................................................................................. 66
Tab. 57 Remote control center identification ........................................................................................... 66
Tab. 58 Machine identification ................................................................................................................. 67
Tab. 59 Other faults and remedies .......................................................................................................... 69
Tab. 60 Warn others that the machine is being serviced. ....................................................................... 71
Tab. 61 Regular maintenance tasks ........................................................................................................ 73
Tab. 62 Oil change intervals lubricants ................................................................................................... 74
Tab. 63 Regular service tasks ................................................................................................................. 74
Tab. 64 Logged maintenance tasks ........................................................................................................ 102
Tab. 65 Spare parts ................................................................................................................................. 103

viii CSD 100/125 T 901726 08 USE
1.1 Using this document

1.1 Using this document
The operating manual is a component of the product. It describes the machine as it was at the time
of first delivery after manufacture.
➤ Keep the operating manual in a safe place throughout the life of the machine.
➤ Supply any successive owner or user with this operating manual.
➤ Please insert any amendment or revision of the operating manual sent to you.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Further documents

Further documents included with this operator manual are:
■ Certificate of acceptance / operating instructions for the pressure vessel
■ User manual for SIGMA CONTROL 2
Missing documents can be requested from KAESER.

➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you provide the data from the nameplate when ordering documents.
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the documenta‐
tion should be referred to KAESER. Correct use of information will be fully supported.
1.4 Symbols and labels

➤ Please note the symbols and labels used in this document.
1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
Warning notices indicate three levels of danger identified by the corresponding signal word:
Signal term Meaning Consequences of disregard
DANGER Warns of an imminent danger Will result in death or severe injury
WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situation May result in a moderate physical injury
Tab. 1 Danger levels and their definition (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:

901726 08 USE CSD 100/125 T 1
The type and source of the imminent danger is shown here!

The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐
jury will occur.
➤ The measures required to protect yourself from danger are shown here.
Warning notes referring to a sub-section or the subsequent action are integrated into the procedure
and numbered as an action.
Example:
1. The type and source of the imminent danger is shown here!
The possible consequences of ignoring a warning are shown here.
If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
injury may occur.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
1.4.2 Potential damage warnings

Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
Warning notices for damages are identified by their signal term.

Signal term Meaning Consequences of disregard
NOTE Warns of a potentially dangerous situation Damage to property is possible
Tab. 2 Danger levels and their definition (damage to property)
Example:
The type and source of the imminent danger is shown here!

Potential effects when ignoring the warning are indicated here.
➤ The protective measures against the damages are shown here.
➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alerts and their symbols

This symbol identifies particularly important information.

2 CSD 100/125 T 901726 08 USE
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
The conditions relevant to safety shown here will help you to avoid dangerous situations.
Option H1 ➤ This symbol denotes lists of actions comprising one stage of a task.
Operating instructions with several steps are numbered in the sequence of the operating steps.
Information relating to one option only are marked with an option code (e.g., H1 indicates that
this section applies only to machines with machine mountings). Option codes used in this oper‐
ator manual are explained in chapter 2.2.
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... as is a solution.
This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
Further information Further subjects are introduced here.

901726 08 USE CSD 100/125 T 3
2 Technical Data
2.1 Nameplate
2 Technical Data
2.1 Nameplate
The machine's nameplate provides the model designation and important technical information.
The nameplate is located on the outside of the machine:

■ above the cooler,
or
■ on the rear of the machine.
➤ Enter here the nameplate data as a reference:
Characteristic Value
Part no.
Year
Serial no.
psig
cfm
Voltage
Hz/RPM
Package FLA
Phase
HP
Wiring Diagram
FOR SERVICE, REFER TO EQUIPMENT NUMBER
Tab. 3 Nameplate
2.2 Options
The table contains a list of possible options. The options for this machine are shown near the
nameplate.
➤ Enter options here for reference:
Option Option code Available?

MODULATING control C1
SIGMA CONTROL 2: C3 ✓
Connection to control technology available
Power supply monitoring C29 —
IT-three-phase network C35 —
Bolt-down machine feet H1
Installed: ✓
Not available: —

4 CSD 100/125 T 901726 08 USE
2 Technical Data
2.3 Weight
Option Option code Available?

Air-cooling K1
Water-cooling: K2
Plate-type heat exchanger
Cooling air filter mat K3
Water-cooling: K9
Bundled-tube heat exchanger
Transformer power supply for refrigerated dryer T2
Heat recovery ΔT=45°F W2
Heat recovery ΔT=99°F W3
Installed: ✓
Not available: —
Tab. 4 Options
2.3 Weight
The weight given is the maximum. Actual weights of individual machines are dependent on equip‐
ment fitted.
CSD 100 CSD 125

Weight [lb] 4510 4720
Tab. 5 Machine weight
2.4 Temperature
CSD 100 CSD 125
Minimum cut-in tempera‐ 40 40
ture [°F]
Typical airend discharge 150 – 200 150 – 200
temperature during oper‐
ation [°F]
Maximum airend dis‐ 230 230
charge temperature [°F]
(automatic safety shut-
down)
* The machine continuously changes the airend discharge temperature corresponding to the am‐
bient temperature.
Tab. 6 Temperature

901726 08 USE CSD 100/125 T 5
2 Technical Data
2.5 Ambient conditions
2.5 Ambient conditions

CSD 100 CSD 125
Maximum elevation amsl* 3000 3000
[ft]
Permissible ambient tem‐ 40 – 115 40 – 115
perature [°F]
Cooling air temperature 40 – 115 40 – 115
[°F]
Inlet air temperature [°F] 40 – 115 40 – 115
*Higher altitudes are permissible only after consultation with the manufacturer.
Tab. 7 Ambient conditions
2.6 Ventilation
The values given are minimum guide values.
CSD 100 CSD 125

Inlet aperture Z see fig‐ 25 / 8.6* 29 / 8.6*
ure 15 [sq.ft.]
Extractor for forced venti‐ 18834 21777
lation: 6474* 7063*
Flow rate [cfm] at
0.4 in.wc
* Option K2/K9
Tab. 8 Ventilation
2.7 Pressure
Maximum working pressure: see nameplate.
Safety relief valve activating pressure [psig]:
Maximum working pres‐ CSD 100 CSD 125

sure [psig]
125 145 145
175 205 205
217 232 232
Tab. 9 Safety relief valve activating pressure

6 CSD 100/125 T 901726 08 USE
2 Technical Data
2.8 Free air delivery (FAD)
2.8 Free air delivery (FAD)

FAD [cfm]:
Maximum working pres‐ CSD 100 CSD 125

sure [psig]
125 494 566
175 410 480
217 332 399
FAD as per ISO 1217:2009. Annex C
Tab. 10 Free air delivery
2.9 Cooling Oil Recommendation

A sticker showing the type of oil filled is located near the oil separator filler.
Information for ordering cooling oil can be found in chapter 11.
2.9.1 Basic Information

Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can form in
compressor cooling oils. These deposits block the flow of lubricant and cause excessive wear and
failure of moving parts. Contamination of the lubricant can allow the formation of acids, causing ex‐
tensive internal corrosion. Water may be condensed decreasing the lubricity.
Lubricants in rotary compressors do much more than lubricate. During the compression process, it
acts as a sealant in the airend which is important for maximum efficiency. The lubricant also ab‐
sorbs much of the heat of compression to cool the airend and reduce the temperature of the com‐
pressed air. It’s not enough that a compressor cooling oil lubricates well, it must stand up to the
heat, pressure and contaminants that are present in every air compressor.
2.9.2 KAESER Lubricants

KAESER synthetic lubricants should be stored in a protected location to prevent contamination. Do
not re-use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic com‐
pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a
fire-resistant fluid. It has a flash point above 460 °F. Since the user has total control over the condi‐
tions of the compressor lubricant, he assumes total responsibility for its safe usage.
Material Safety Data Sheets are available for each lubricant from your authorized
KAESER SERVICE representative.
Regardless of the lubricant selected, the KAESER SIGMA lubricants will separate readily from wa‐
ter. If condensate occurs it can easily be removed. Let the compressor sit so that any water can
drain back to the separator tank and separate to the bottom. See chapter 10.17 proper draining
procedure.
KAESER has several lubricants available that are specially formulated to match these demands.
They feature excellent lubricity, outstanding demulsibility (ability to separate from water), and long
life.

901726 08 USE CSD 100/125 T 7
2 Technical Data
2.10 Cooling oil charge
M-SERIES
■ M-Series SIGMA compressor cooling oils are semi-synthetic lubricants.
■ M-Series SIGMA compressor cooling oils are the highest quality petroleum lubricants. M–460
is specially blended to provide reliable performance in KAESER screw compressors.
S-SERIES
■ S-Series SIGMA compressor cooling oils are synthetic lubricants.
■ S-Series SIGMA compressor cooling oils are formulated from the most advanced synthetic lu‐
bricants. These ”synthetic” lubricants begin as high quality petroleum feed stock. They are then
refined, processed and purified into fluids with very consistent molecular structure. These oils
are carefully blended to produce extremely consistent lubricants with superior properties.
SIGMA synthetic lubricants feature all the advantages of both PAO and diester fluids.
■ S-460 lubricant is recommended for compressors operating in ambient temperatures between
40 °F and 105 °F.
Specialty KAESER LUBRICANTS

■ S-680 lubricant may be used when ambient temperatures are always between 70 °F and
105 °F.
■ FG-460 synthetic hydrocarbon based food grade lubricant is designed for use in rotary screw
compressors in the application where incidental food contact may occur with the discharge air.
This lubricant meets the requirements of the FDA Regulation 21 CFR §178.3570 and is
USDA H-1approved and NSF certified. FG-460 is approved for canning, food packing, meat
and poultry processing and other applications where incidental food contact may occur.
2.10 Cooling oil charge

The required cooling oil charge depends on the optional heat recovery system. For machines with
options W2 or W3, the additional volume required for the heat recovery must be added to the
charge.
Option K1 Air cooling
CSD 100 CSD 125

Fluid volume* [gal] 13.7 13.7
Topping off volume [qt] 5.3 5.3
*Plus the oil volume of the optional heat recovery system.
Tab. 11 Cooling oil charge (Option K1)
Option K2 Water cooling (plate-type heat exchanger)
CSD 100 CSD 125

Topping up volume [qt] 5.3 5.3

8 CSD 100/125 T 901726 08 USE
2 Technical Data
2.11 Motors and power
Option K9 Water cooling (bundled pipe heat exchanger)
CSD 100 CSD 125

Topping up volume [qt] 5.3 5.3
Option W2/W3 Heat recovery
Option W2 CSD 100 CSD 125

Additional charge vol‐ 9.5 9.5
ume [qt]
Tab. 14 Cooling oil charge (Option W2)
Option W3 CSD 100 CSD 125

Additional charge vol‐ 5.9 5.9
ume [qt]
Tab. 15 Cooling oil charge (Option W3)
2.11 Motors and power

2.11.1 Compressor drive motor
CSD 100 CSD 125
Rated power [hp] 100 125
Rated speed [rpm] 3585 3584
Protection rating TEFC TEFC
Motor bearing re-greas‐ 2000 2000
ing interval [h]
Grease requirement, 20 25
each bearing [g]
h = operating hours
Tab. 16 Compressor drive motor
2.11.2 Option K1
Fan motor
CSD 100 CSD 125
Rated power [hp] 1.4 1.4
h = operating hours

901726 08 USE CSD 100/125 T 9
2 Technical Data
2.12 Noise emission
CSD 100 CSD 125

Motor bearing re-greas‐ 6000 6000
ing interval [h]
Grease requirement, 5 5
each bearing [g]
h = operating hours
Tab. 17 Fan motor (Option K1)
2.11.3 Option K2/K9

Fan motor
CSD 100 CSD 125
Rated power [hp] 0.16 0.16
Rated speed [rpm] 2700 2700
Tab. 18 Fan motor (Option K2/K9)
2.12 Noise emission

Mains frequency CSD 100 CSD 125
Noise emission [dB(A)] 72 / 71* 73 / 72*
Noise pressure level as per ISO 2151 and the basic standard ISO 9614-2; operation with maxi‐
mum working pressure; uncertainty: ±3 dB(A)
* Option K2/K9
Tab. 19 Noise emission
2.13 Power Supply

Basic requirements
The machine is designed for an electrical supply according to National Electric Code (NEC,
NFPA 70 and NFPA 79). In the absence of any user-specified alternatives, the limits given in these
standards must be adhered to. Consult manufacturer for any other specific power supply.
The incoming line within the control panel should be as short as possible.
If external sensors or communications lines are to be connected to the machine, use shielded ca‐
bles and insert the same through EMC fittings into the control panel.
Three-phase
Do NOT operate package on any unsymmetrical power supply. Also do NOT operate package on
power supplies such as a three-phase wye system with center point not solidly grounded or three-
phase (open) delta.
The machine requires a symmetrical three-phase power supply transformer with a WYE configura‐
tion output as shown in Figure 1 and Figure 2. In a symmetrical three phase supply the phase an‐
gles and voltages are all the same.

10 CSD 100/125 T 901726 08 USE
2 Technical Data
2.14 Power supply specifications
Other power supplies are not allowed.
Fig. 1 Three-phase (wye system); 4 wire; center point solidly grounded
Fig. 2 Three-phase (wye system); 3 wire; center point solidly grounded
Further information The wiring diagram in chapter 13.4 contains further details regarding the power supply connection.
2.14 Power supply specifications

The following multi-strand copper core wires are given according to 2017 NEC 310.15 and ta‐
ble 310.15(B)(16) adjusted for 40 °C ambient temperature.
If other local conditions prevail, like for example high temperature, the cross section should be
checked and adjusted according to 2017 NEC 110.14(C), 220.3, 310.15, table 310.15(B)(2)(a), ta‐
ble 310.15(B)(3)(a), 430.6, 430.22, 430.24, 670.4(A) and other local codes.
Dual element time delay fuses are selected according to 2017 NEC 240.6, 430.52 and ta‐
bles 430.52, 430.248 and 430.250.
We recommend a ground conductor the same size as the current carrying conductors, if local co‐
des allow. The minimum size as pointed out in 2017 NEC table 250.122 is NOT recommended.
Further information The electrical diagram in chapter 13.4 contains further specifications for electrical connection.
Rated power supply: 230V / 3 / 60Hz
CSD 100 CSD 125

Pre-fuse [A] 400 450
Supply per phase and 2x AWG4/0 2x MCM250 / 2x AWG4/01)
ground (75 °C)
Consumption [A] 295 / 2901) 318 / 3121)
1)
Option K2/K9
Tab. 20 Power supply details (230V / 3 / 60Hz)
Rated power supply 380V / 3 / 60Hz
CSD 100 CSD 125

Pre-fuse [A] 250 300 / 2501)
1)
Option K2/K9

901726 08 USE CSD 100/125 T 11
2 Technical Data
2.15 Water-cooling
CSD 100 CSD 125

Supply per phase and 2x AWG1 2x AWG1/0
ground (75 °C)
Consumption [A] 176 / 1731) 200 / 1981)
1)
Option K2/K9
Rated power supply: 460V / 3 / 60Hz
CSD 100 CSD 125

Pre-fuse [A] 200 225
Supply per phase and 2x AWG2 2x AWG1
ground (75 °C)
Consumption [A] 144 / 1411) 159 / 1571)
1)
Option K2/K9
Rated power supply 575V / 3 / 60Hz
CSD 100 CSD 125

Pre-fuse [A] — —
Supply per phase and — —
ground (75 °C)
Consumption [A] — / —1) — / —1)
1)
Option K2/K9
2.15 Option K2/K9

Water-cooling
Cooling oil may contaminate the cooling water if a leak occurs.
➤ A special heat exchanger must be used for heating drinking water.
The specific heat capacity and required volume flow rate of the cooling water changes if anti‐
freeze is added.
➤ Match the parameters of the water cooling to the properties of the cooling water.
➤ Consult an authorized KAESER SRVICE representative to ensure optimum cooling-sys‐
tem performance.
➤ Comply with the specified minimum requirements for the cooling water in order to avoid
downtimes due to corrosion, calcification and contamination.
It is imperative that measures for cooling water treatment and filtration are implemented and
performed.
KAESER can provide the names of companies specializing in cooling water analysis and the
supply of suitable treatment devices.

12 CSD 100/125 T 901726 08 USE
2 Technical Data
2.15 Water-cooling
The following design types are available:

■ Option K2: Water cooling with plate heat exchanger: Chapter 2.15.1
■ Option K9: Water cooling with bundled pipe heat exchanger: Chapter 2.15.2
Open cooling system
An open cooling system may be a cooling circuit with open cooling towers for cooling via evapora‐
tion. As a portion of the cooling water evaporates, it must be replenished regularly. During evapora‐
tion, the material content of the cooling water concentrates and the contact with ambient air can
contaminate the cooling water. When replenishing cooling water, you must ensure the minimum re‐
quirements for the cooling water.
Closed cooling system
In a closed cooling system, the cooling water has not contact with the atmosphere. Thus, it cannot
be contaminated by the atmosphere or enriched with oxygen, for example.
Continuous-flow cooling system
A continuous-flow cooling system is an open cooling system. Ground, surface or drinking water cir‐
culate once through the cooling system.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connec‐
tion ports.
2.15.1 Option K2
Water cooling (plate-type heat exchanger)
There are typical layout examples. Conditions for each individual installation could vary from
these guidelines.
➤ If required, enter your individual values in the prepared table.
➤ If the design data differ, request that the settings in SIGMA CONTROL 2 are checked by
an authorized KAESER service representative.
The primary winding of the heat exchanger is connected to the machine. The specifications
refer to the secondary side of the heat exchanger.
Individual design data
My value
Cooling water tempera‐
ture rise [°F]
Flow rate [gpm]
Pressure drop [psi]
Tab. 24 Water cooling K2: Individual design data

901726 08 USE CSD 100/125 T 13
2 Technical Data
2.15 Water-cooling
2.15.1.1 Component specification
Feature Value
Material (Heat exchang‐ 1.4401
er)
Braze (Heat exchanger) Copper (Cu)
Max. working pres‐ 145
sure [psig]
Minimum permissible in‐ 41
let temperature [°F]
Max. permissible inlet 104
temperature* [°F]
Continuously possible 122
outlet temperature [°F]
Maximum permissible 158
(Component limit value)
flow rate [gpm]
Unsuitable cooling media Seawater
Consult KAESER about water types.
* Consult KAESER about higher values.
Tab. 25 Component specification (Option K2)
2.15.1.2 Cooling water quality
Characteristics/content Closed cooling sys‐ Open cooling system

tem
pH value 7.5 – 9.0 7.5 – 9.0
Hardness [°dH] 0 – 20 0 – 20
Carbonate hardness [°dH] <20 <4
Chlorides (Cl) [mg/l] <100 <100
Dissolved iron (Fe) [mg/l] <0.5 <0.2
Sulphate (SO4) [mg/l] <100 <100
HCO3/SO4 ratio >1 >1
Electrical conductivity [µS/cm] 10 – 800 10 – 1500
Ammonia (NH4+) [mg/l] <1 <1
Manganese (Mn), dissolved [mg/l] <0.1 <0.1
Glycol [%] 20 – 40 —
Solids (particle size) [mm] <0.1 <0.1
Bacterial count [CFU*/ml] 10000 10000
* CFU: colony-forming units

14 CSD 100/125 T 901726 08 USE
2 Technical Data
2.15 Water-cooling

tem
Suspended solids [ppm] <20 <20
(portion of undissolved matter)
Tab. 26 Cooling water quality (Plate-type heat exchanger)
2.15.1.3 Design data for the cooling system
Cooling water temperature rise 20 °F
CSD 100 CSD 125

Maximum permissible in‐ 104 104
Flow rate [gpm] 33 37
Pressure drop [psi] 7.3 8.7
Tab. 27 Cooling water temperature (ΔT= 20 °F)
CSD 100 CSD 125

Tab. 28 Cooling water temperature (ΔT= 50 °F)
2.15.2 Option K9
Water cooling (Bundled pipe heat exchanger)
There are typical layout examples. Conditions for each individual installation could vary from
these guidelines.
The primary winding of the heat exchanger is connected to the machine. The specifications
refer to the secondary side of the heat exchanger.
My value
Cooling water tempera‐
ture rise [°F]
Volume flow rate [gpm]
Pressure drop [psi]
Tab. 29 Water cooling K9: Individual design data

901726 08 USE CSD 100/125 T 15
2 Technical Data
2.15 Water-cooling
2.15.2.1 Component specification
Feature Value
Material (Heat exchang‐ CuNi10Fe
er)
sure [psig]
temperature* [°F]
Maximum permissible 71.8
flow rate [gpm]
Tab. 30 Component specification (Option K9)
2.15.2.2 Cooling water quality

tem
pH value 6.0 – 9.0 6.5 – 9.0
Hardness [°dH] 0 – 20 0 – 20
Carbonate hardness [°dH] <20 <4
Chlorides (Cl) [mg/l] <500 <250
Dissolved iron (Fe) [mg/l] <0.5 <0.2
Sulphate (SO4) [mg/l] <100 <100
HCO3/SO4 ratio >1 >1
Electrical conductivity [µS/cm] 10 – 2500 10 – 2500
Ammonia (NH4 ) [mg/l]
+ <2 <1
Manganese (Mn), dissolved [mg/l] <0.1 <0.1
Glycol [%] 20 – 40 —
Solid particles [mm] <0.2 <0.2
(Particle size)
Bacterial count [CFU*/ml] 10000 10000

16 CSD 100/125 T 901726 08 USE
2 Technical Data
2.16 Heat recovery

tem
Suspended solids [ppm] <20 <20
Tab. 31 Cooling water quality (Bundled-pipe heat exchanger)
2.15.2.3 Design data for the cooling system
CSD 100 CSD 125

Tab. 32 Cooling water temperature (ΔT=20 °F)
CSD 100 CSD 125

Tab. 33 Cooling water temperature (ΔT=50 °F)
2.16 Option W2/W3

Heat recovery
These are typical layout examples. Conditions for each individual installation could vary from these
guidelines.
The reasons may be (examples):

■ Fluctuating condensate flow
■ Working pressure
■ Inlet conditions
■ Ambient conditions
■ Machine settings
Water is generally the heat-receiving medium. The water must meet the quality specified below in
order not to damage the heat exchanger.

901726 08 USE CSD 100/125 T 17
2 Technical Data
2.16 Heat recovery
The specified flow rate relates to the maximum available heat capacity.
KAESER SERVICE.
➤ Consult KAESER SERVICE if you wish to use a different heat-receiving medium.
The primary side of the heat exchanger is connected to the cooling oil circuit of the machine.
The specifications refer to the secondary side of the heat exchanger.
My value
Heating from [°F]
Heating to [°F]
Temperature difference
(ΔT) [°F]
Maximum available heat
output [kW]
(relative to ___ psig work‐
ing pressure)
Flow rate [gpm]
Pressure drop [psi]
Tab. 34 Heat recovery: Individual design data
Component specification
Feature Value
Material 1.4401
Braze Copper (Cu)
sure [psig]
temperature* [°F]
flow rate [gpm]
Tab. 35 Specification: Heat exchanger (Option W2/W3)

18 CSD 100/125 T 901726 08 USE
2 Technical Data
2.16 Heat recovery
Quality of the heat receiving medium
Characteristics/content Value
pH value 7.5 – 9.0
Hardness [°dH] 0 – 20
Carbonate hardness* [°dH] <20
Chlorides (Cl) [mg/l] <100
Dissolved Iron (Fe) [mg/l] <0.5
Sulphate (SO4) [mg/l] <300
HCO3/SO4 ratio >1
Electrical conductivity [µS/cm] 10 – 800
Ammonia (NH4+) [mg/l] <1
Manganese (Mn), dissolved [mg/l] <0.1
Glycol [%] 20–40
Solids (particle size) [mm] <0.1
Bacterial count [CFU*/ml] 10,000
Suspended solids [ppm] <20
Tab. 36 Quality of the heat receiving medium
Heat capacity
Maximum heat capacity CSD 100 CSD 125

available
[kW] 69 80
[MJ/h] 247 286
[kcal/h] 58960 68390
Tab. 37 Heat capacity (Option W2/W3)
Option W2 Flow rate for heating from 115°F to 160°F (equates to ΔT= 45°F)
CSD 100 CSD 125

Volume flow rate [gpm] 10 12
Tab. 38 Flow rate / pressure drop (option W2)
Option W3 Flow rate for heating from 60°F to 160°F (equates to ΔT= 100°F)
CSD 100 CSD 125

Volume flow rate [gpm] 4.4 5.7
Tab. 39 Flow rate / pressure drop (option W3)

901726 08 USE CSD 100/125 T 19
2 Technical Data
2.17 Refrigerated dryer
2.17 Refrigerated dryer

Compressed air system
ABT 165
Pressure drop [psi] 15
(referenced at 100 psi
working pressure)
Maximum permitted 232
working pressure [psi]
Tab. 40 Refrigerated dryer: Compressed air system
Refrigerant circuit
The refrigerated dryer contains a refrigerant that is classified as a fluoridated global warming gas.
This refrigerant is required for the function.
ABT 165
Refrigerant R-134a
Global warming potential 1430
(GWP)
Charge quantity1) 2) [lb] 4.2
Charge quantity1) as CO2 2.6
equivalent [t]
Maximum working pres‐ 305
sure [psi]
(high pressure end)
Maximum working pres‐ 232
sure [psi]
(low pressure end)
Safety pressure monitor: 305
Cut-out pressure [psi]
1)
50Hz / 60Hz
2)
Volume of fluoridated global warming gases for which the refrigerant system was designed.
Tab. 41 Refrigerated dryer: Refrigerant circuit

20 CSD 100/125 T 901726 08 USE
3.1 Basic instructions

The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ danger to life and limb of the operator or third parties,
■ damages to the machine and other material assets.
Disregard of warning or safety instructions can cause serious injuries!
➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
which it is intended; observe all safety measures and the instructions in the operator manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety!
3.2 Specified use

The machine is intended solely for generating compressed air for industrial use. Any other use is
considered incorrect. The manufacturer is not liable for any damages that may result from incorrect
use. The user alone is liable for any risks incurred.
➤ Keep to the specifications listed in this service manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
➤ Do not use compressed air for breathing purposes unless it is specifically treated.
➤ Do not use compressed air for any application that will bring it into direct contact with food
products unless it is specifically treated.
3.3 Improper use

Improper usage can cause damage to property and/or (severe) injuries.
➤ Only use the machine as intended.
➤ Never direct compressed air at persons or animals.
➤ Use hot cooling air for heating purposes only if there is no risk to the health of humans or ani‐
mals. If necessary, hot cooling air should be treated by suitable means.
➤ Do not allow the machine to take in toxic, acidic, flammable of explosive gases or vapors.
➤ Do not operate the machine in areas in which specific requirements with regard to explosion
protection are in force.
3.4 User's Responsibilities

3.4.1 Observe statutory and universally accepted regulations
This is, for example, nationally applied European directives and/or valid national legislation, safety
and accident prevention regulations.
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the machine.

901726 08 USE CSD 100/125 T 21
3.5 Dangers
3.4.2 Qualified personnel

These are people who, by virtue of their training, knowledge and experience as well as their knowl‐
edge of relevant regulations can assess the work to be done and recognize the possible dangers
involved.
Authorized operators possess the following qualifications:

■ are of legal age,
■ are conversant with and adhere to the safety instructions and sections of the operator manual
relevant to operation,
■ have received adequate training and authorization to operate electrical and compressed air de‐
vices.
■ Additional qualifications for compressors with refrigerated dryers:
─ Adequate training and authorization on refrigeration devices.
Authorized installation and maintenance personnel have the following qualifications:

■ are of legal age,
■ have read, are conversant with and adhere to the safety instructions and sections of the opera‐
tor manual applicable to installation and maintenance,
■ are fully conversant with the safety concepts and regulations of electrical and compressed air
engineering,
■ are able to recognize the possible dangers of electrical and compressed air devices and take
appropriate measures to safeguard persons and property,
■ have received adequate training and authorization for the safe installation and maintenance on
this equipment.
■ Additional qualifications for compressors with refrigerated dryers:
─ fully conversant with the safety concepts and regulations concerning refrigeration devices,
─ must be able to recognize the possible dangers of refrigeration devices and take appropri‐
ate measures to safeguard persons and property.
➤ Ensure that operating, installation and maintenance personnel are qualified and authorized to
carry out their tasks.
3.4.3 Adherence to inspection schedules and accident prevention regulations

The machine is subject to local inspection schedules.
➤ Ensure that local inspection schedules are adhered to.
3.5 Dangers
Basic instructions
The following describes the various forms of danger that can occur during machine operation.
Basic safety instructions are found in this operator manual at the beginning of each chapter in the
section entitled “Safety”.
Warning instructions are found before a potentially dangerous task.

22 CSD 100/125 T 901726 08 USE
3.5 Dangers
3.5.1 Safely dealing with sources of danger

The following describes the various forms of danger that can occur during machine operation.
Electricity
Touching voltage carrying components can result in electric shocks, burns or death.
➤ Allow only qualified and authorized electricians or trained personnel under the supervision of a
qualified and authorized electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations.
➤ Before commissioning or re-commissioning the machine, the user must ensure adequate pro‐
tection against electric shock from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
➤ Switch off any external power sources.
These could be connections to floating relay contacts or the electrical machine heating, for ex‐
ample.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in proper condition.
Forces of compression
Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury
or death. The following information concerns work on components that could be under pressure.
➤ Close shut-off valves or otherwise isolate the machine from the distribution network to ensure
that no compressed air can flow back into the machine.
➤ Depressurize all pressurized components and enclosures.
➤ Do not carry out welding, heat treatment or mechanical modifications on pressurized compo‐
nents (e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.
Compressed air quality
The composition of the compressed air must be suitable for the actual application in order to pre‐
clude health and life-threatening dangers.
➤ Use appropriate systems for air treatment before using the compressed air from this machine
as breathing air and/or for the processing of food products.
➤ Use food-grade cooling oil whenever compressed air is to come into contact with food prod‐
ucts.
Spring forces
Springs under tension or compression store energy. Uncontrolled release of this energy can cause
serious injury or death.
Minimum pressure / check valves, safety relief valves and inlet valves are powerfully spring-loaded.
➤ Do not open or dismantle any valves.

901726 08 USE CSD 100/125 T 23
3.5 Dangers
Rotating components
Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result
in serious injury.
➤ Do not open the enclosure while the machine is activated.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of any
voltage.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Make sure all covers and safety guards are in place and secured before re-starting.
Temperature
High temperatures are generated during compression. Touching hot components may cause inju‐
ries.
➤ Avoid contact with hot components.
These include, for example, compressor airends or blocks, oil and compressed air lines, cool‐
ers, oil separator tanks, motors and machine heaters.
➤ Wear protective clothing.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapors or parts of the machine.
Noise
The enclosure absorbs the machine noise to a tolerable level. This function will be effective only if
the enclosure is closed.
➤ Operate the machine only with intact sound insulation.
➤ Wear hearing protection if necessary.
The blowing-off of the safety relief valve can be particularly loud.
Operating fluids/materials
The used operating fluids and materials can cause adverse health effects. Suitable safety meas‐
ures must be taken in order to prevent injuries.
➤ Strictly forbid fire, open flame and smoking.
➤ Follow safety regulations when dealing with oils, lubricants and chemical substances.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapor.
➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.
Unsuitable spare parts
Unsuitable spare parts compromise the safety of the machine.

➤ Use only spare parts approved by the manufacturer for use in this machine.
➤ Use only genuine KAESER replacement parts on pressure bearing parts.

24 CSD 100/125 T 901726 08 USE
3.5 Dangers
Conversion or modification of the machine
Modifications, additions to and conversions of the machine or the controller can result in unpredict‐
able dangers.
➤ Do not convert or modify the machine!
➤ Obtain written approval by the manufacturer prior to any technical modification or expansion of
the machine, the controller, or the control programs.
Extending or modifying the compressor station
If dimensioned appropriately, safety relief valves reliably prevent an impermissible rise in pressure.
New dangers may arise if you modify or extend the compressed air station.
➤ When extending or modifying the compressed air system:
Check the blow-off capacity of safety relief valves on air receivers and compressed air lines
before installing a new machine.
➤ If the blow-off capacity is insufficient:
Install safety relief valves with larger blow-off capacity.
3.5.2 Safe machine operation

The following is information supporting you in the safe handling of the machine during individual
product life phases.
Personal protective equipment
When working on the machine you may be exposed to dangers that can result in accidents with
severe adverse health effects.
➤ Wear protective clothing as necessary.
Suitable protective clothing (examples):

■ Safety workwear
■ Protective gloves
■ Safety boots
■ Eye protection
■ Ear protection
Transporting
The weight and size of the machine require safety measures during its transport to prevent acci‐
dents.
➤ Use suitable lifting gear that conforms to local safety regulations.
➤ Allow transportation only by personnel trained in the safe movement of loads.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the center of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
➤ Do not step onto machine components to climb up the machine.
Assembly
➤ Only use only electrical cables that are suitable and approved for the surroundings and electri‐
cal loads applied.

901726 08 USE CSD 100/125 T 25
3.5 Dangers
➤ Never dismantle compressed air pipes until they are fully vented.
➤ Only use pressure lines that are suitable and approved for the maximum working pressure and
the intended medium.
➤ Do not allow connection pipes to be placed under mechanical stress.
➤ Do not induce any forces into the machine via the connections, so that the compressive forces
must be balanced by bracing.
Positioning
A suitable installation location for the machine prevents accidents and faults.
➤ Install the machine in a suitable compressor room.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements regarding explosion protection are in
force.
➤ Ensure adequate ventilation.
➤ Place the machine in such a manner that the working conditions in its environment are not im‐
paired.
➤ Comply with limit values for ambient temperature and humidity.
➤ The intake air must not contain any damaging contaminants,
Damaging contaminants are for instance: explosive or chemically instable gases and vapors,
acid or base forming substances such as ammonia, chlorine or hydrogen sulfide.
➤ Do not position the machine in warm cooling outlet air from other machines.
Commissioning, operation and maintenance
During commissioning, operation and maintenance you may be exposed to dangers resulting from,
e.g., electricity, pressure and temperature. Careless actions can cause accidents with severe ad‐
verse effects for your health.
➤ Allow maintenance work to be carried out only by authorized personnel.
➤ Wear close-fitting, flame-resistant clothing. Wear protective clothing as necessary.
➤ Switch off and lock out the power supply isolating device and verify the absence of voltage.
➤ Check that there is no voltage on floating relay contacts.
➤ Close shut-off valves or otherwise isolate the machine from the compressed air network to en‐
sure that no compressed air can flow back into the machine.
➤ De-pressurize all pressurized components and enclosures.
➤ Allow the machine to cool down.
➤ Do not open the cabinet while the machine is switched on.
➤ Use only spare parts approved by KAESER for use in this machine.

26 CSD 100/125 T 901726 08 USE
3.6 Safety devices
➤ Carry out regular inspections:

for visible damages,
of safety installations,
of the EMERGENCY STOP push button,
of any components requiring monitoring.
➤ Pay particular attention to cleanliness during all maintenance and repair work. Cover compo‐
nents and openings with clean cloths, paper or tape to keep them clean.
➤ Do not leave any loose components, tools or cleaning rags on or in the machine.
➤ Components removed from the machine can still be dangerous.
Do not attempt to open or destroy any components taken from the machine.
De-commissioning, storage and disposal
Improper handling of old operating fluids and components represent a danger for the environment.
➤ Drain off fluids and dispose of them according to environmental regulations.
These include, for example, compressor oil and cooling water.
➤ Have refrigerant disposed of by authorized bodies only.
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organizational Measures

➤ Designate personnel and their responsibilities.
➤ Give clear instructions on reporting faults and damage to the machine.
➤ Give instructions on fire reporting and fire-fighting measures.
3.5.4 Danger Areas

The table gives information on the areas dangerous to personnel.
Only authorized personnel may enter these areas.
Activity Danger area Authorized personnel

Transport Within a 10 ft radius of the machine. Installation personnel for transport
preparation.
No personnel during transport.
Beneath the lifted machine. No personnel!
Installation Within the machine. Installation personnel
Within 3 ft radius of the machine and its sup‐
ply cables.
Operation Within a 3 ft radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 3 ft radius of the machine.
Tab. 42 Danger Areas
3.6 Safety devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.

901726 08 USE CSD 100/125 T 27
3.7 Working life of safety functions
➤ Regularly check safety devices for their correct function.

➤ Do not remove or obliterate labels and notices.
➤ Ensure that labels and notices are clearly legible.
Further information More information on safety devices is contained in chapter 4, section 4.2.2.
3.7 Working life of safety functions

The safety-relevant functions of the safety devices equipped with this machine are designed for a
working life of 20 years. The working life starts with original machine commissioning, and is not ex‐
tended by times during which the machine is not in use.
The following functions are affected:

■ Resistance thermometer (Pt100 sensor for measuring the compression discharge temperature)
■ EMERGENCY STOP push button
■ Main contactor
1. The functions of the safety components must be replaced by an authorized KAESER service
representative after a working life of 20 years.
2. Have an authorized KAESER service representative check the reliability of the safety func‐
tions.
3.8 Safety signs

The illustration shows the position of the safety signs on the machine. The table lists the various
safety signs used and their meanings.

28 CSD 100/125 T 901726 08 USE
3.8 Safety signs
Fig. 3 Location of safety signs
Item Symbol Meaning

8 Danger of fatal injury from touching electrically live components!
➤ Switch off and lock out the power supply disconnecting device and check that
no voltage is present.
9 Personal injury or damage to the machine by incorrect operation!
➤ Read and understand the service manual and all safety signs before switching
on this machine.
Machine starts automatically!
Severe injury could result from rotating components, electrical voltage, and air
pressure.
no voltage is present before opening any machine enclosure or guard.
11 Injury and/or contamination can result from breathing compressed air!
Contamination of food can result from using untreated compressed air for food pro‐
cessing!
➤ Never breathe untreated compressed air.
➤ Air from this compressor must meet OSHA 29CFR1910.134 and
FDA 21CFR178.3570 standards, if used for breathing or food processing. Use
proper compressed air treatment.

901726 08 USE CSD 100/125 T 29
3.8 Safety signs
Item Symbol Meaning

12 Rotating parts!
Severe injury, especially of the eyes, could result while the fan is rotating.
➤ Prevent all materials from falling into the fan guard.
➤ Never work over the running machine.
13 Hot surface can cause burns!
➤ Let the machine cool down.
➤ Wear long-sleeved garments (not synthetics such as polyester) and protective
gloves.
15 Bearing damage due to re-greasing in standstill!
➤ Re-grease the bearings only with the motor running.
➤ Use only ESSO UNIREX N3 bearing grease.
➤ For lubrication interval and volume required, please refer to service manual.
23 Serious injury or death can result from loosening or opening component that is un‐
der pressure and heavily spring loaded!
➤ Do not open or dismantle the valve.
➤ Contact an authorized KAESER service representative if a fault occurs.
24 Serious injury or death can result from loosening or opening component under
pressure!
➤ Secure so that the machine stays depressurized.
➤ Check that the machine is depressurized before beginning any work on the
system.
25 Ear damage and burns can result from loud noise and/or oil mist when the safety
relief valve opens!
➤ Wear ear protection and protective clothing.
➤ Close all access doors and cover panels.
26 Rotating coupling!
Severe injury could result from touching the coupling while it is rotating.
➤ Never switch the machine on without the guard in place over the coupling.
no voltage is present.
27 Risk of electric shock!
If the interrupter has tripped, current-carrying components of the controller should
be examined and replaced if damaged to reduce the risk of fire or electric shock.
28 Risk of electric shock!
To maintain overcurrent short-circuit and ground-fault protection, the manufactur‐
er's instructions for setting the interrupter must be followed to reduce the risk of fire
or electric shock.

30 CSD 100/125 T 901726 08 USE
3.9 Emergency situations
Item Symbol Meaning

33 High protective conductor current!
Touching electrically live components can cause serious injury or death.
➤ Isolate completely from the power supply (all conductors) and ensure the sup‐
ply cannot be switched on again (lock out).
➤ Wait at least 5 minutes.
➤ Check that no voltage is present.
34 HAZARDOUS VOLTAGE!
Touching electrically live components can cause serious injury or death.
➤ Isolate completely from the power supply (all conductors) and ensure the sup‐
ply cannot be switched on again (lock out).
➤ Check that no voltage is present.
➤ Before starting work on the frequency converter or intermediate circuit capaci‐
tors, wait at least 5 minutes.
Tab. 43 Safety signs

3.9.1 Correct fire fighting
Suitable measures
Calm and prudent action can safe lives in the event of a fire.
➤ Keep calm.
➤ Give the alarm.
➤ Shut off supply lines if possible.
Main disconnecting device (all poles)
Cooling water (if present)
Heat recovery (if present)
➤ Warn and move endangered personnel to safety.
➤ Help incapacitated persons.
➤ Close the doors.
➤ When trained accordingly: Attempt to extinguish the fire.
Extinguishing substances
➤ Suitable extinguishing media:

Foam
Carbon dioxide
Sand or soil
➤ Unsuitable extinguishing media:
Strong jet of water
3.9.2 Treating injuries from handling cooling oil

Eye contact
Cooling oil can cause irritation.

901726 08 USE CSD 100/125 T 31
➤ Rinse open eyes thoroughly for a few minutes under running water.
➤ Seek medical help if irritation persists.
Skin contact
Cooling oil may irritate after prolonged contact.

➤ Wash thoroughly with skin cleaner, then with soap and water.
➤ Contaminated clothing should be dry-cleaned before reuse.
Inhalation
Cooling oil mist may make breathing difficult.

➤ Clear air passages of oil mist.
➤ Seek medical help if difficulty with respiration continues.
Ingestion
➤ Wash out the mouth immediately.

➤ Do not induce vomiting.
➤ Seek medical aid.
3.9.3 Injury from Handling Refrigerant

Eye contact:
Severe eye irritation, watering, reddening and swelling of the eyelids.

Risk of caustic burns and frostbite.
➤ Open eyelids wide to allow product to evaporate.
➤ Hold the eyelid wide and rinse the eye with running water.
➤ Consult an ophthalmologist if you experience lasting pains.
Skin contact:
Initially a sensation of chill, skin may redden subsequently.

Risk of frostbite.
➤ Allow the product to evaporate.
➤ Rinse with lukewarm water.
➤ Consult a physician if experiencing lasting pain or reddened skin.
Inhalation:
At high concentrations, risk of cardiac irregularity (arrhythmia).

At very high concentration, risk of asphyxia caused by oxygen deficiency.
➤ Remove victim to the fresh air.
➤ If necessary Respiration with respirator or administration of oxygen.
➤ Consult a physician if experiencing breathing or nerve complaints.

32 CSD 100/125 T 901726 08 USE
3.10 Warranty
3.10 Warranty
This operator manual contains no independent warranty commitment. Our general terms and con‐
ditions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended un‐
der the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with the user
to determine its suitability for his specific application.
In addition, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ unauthorized modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair includes the use of original spare parts and operating materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.
3.11 Environmental protection

The operation of this machine may cause dangers for the environment.
➤ Do not allow cooling oil to escape to the environment or into the sewage system.
➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
mental protection regulations.
➤ Observe national regulations.
This applies particularly to parts contaminated with compressor cooling oil.

901726 08 USE CSD 100/125 T 33
4.1 Enclosure

4.1 Enclosure
Fig. 4 Enclosure overview

1 Control cabinet door 3 Access door
2 Latch 4 Panel (removable)
The enclosure, when closed, serves various functions:

■ Sound insulation
■ Protection against contact with components
■ Cooling air flow
The enclosure is not suitable for the following uses:

■ Walking on, standing or sitting on.
■ As resting place or storage of any kind of load.
Safe and reliable operation is only assured with the enclosure closed.
Access doors are hinged to swing open and removable panels can be lifted off.
Latches are released by a key supplied with the machine.
4.2 Machine function

The description uses an air-cooled machine as an example.

34 CSD 100/125 T 901726 08 USE
Fig. 5 Machine overview

1 Inlet valve 8 Air filter
2 Minimum pressure check valve 9 Oil/air cooler
3 Compressor motor 10 Add-on cabinet for refrigeration dryer
4 Oil filter 11 Cyclone separator
5 Airend 12 Condensate drain
6 Control cabinet 13 Fan motor (speed controlled)
7 Oil separator tank
Ambient air is cleaned as it is drawn in through the filter 8 .

The air is then compressed in the airend 5 .
The airend is driven by an electric motor 3 .
A speed-controlled electric motor 13 drives the fan used for machine cooling.
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the ro‐
tors themselves and between them and the airend casing. This direct cooling in the compression
chamber ensures a very low airend discharge temperature.
Cooling oil recovered from the compressed air in the oil separator tank 7 gives up its heat in the oil
cooler 9 . The oil then flows through the filter 4 and back to the point of injection. Air pressure
within the machine keeps the oil circulating. A separate pump is not necessary.
A temperature-regulating valve driven by an electric motor keeps the cooling oil at optimum tem‐
perature. Together with SIGMA CONTROL 2, the electronic thermal management (Electronic
Thermo Management – ETM) uses various parameters to keep the cooling oil temperature as low
as possible. A low cooling oil temperature increases the machine's energy efficiency.
Compressed air, freed of cooling oil in the oil separator tank 7 , flows through the minimum pres‐
sure check valve 2 into the air cooler 9 . The minimum pressure check valve ensures that there is
always a minimum internal pressure sufficient to maintain cooling oil circulation in the machine.
The aftercooler cools the compressed air temperature to approximately 9°F to 18°F above the am‐
bient temperature. A major portion of the existing humidity is removed from the compressed air and
drained via the cyclone separator 11 with condensate drain 12 .

901726 08 USE CSD 100/125 T 35
4.2.1 Refrigerated dryer
Fig. 6 Refrigerated dryer

10 Refrigerated dryer
12 Condensate drain
The downstream refrigerated dryer removes moisture from the compressed air.
The condensate is removed via a condensate drain.
4.2.2 Safety devices

The following safety devices are provided and must not be modified or disabled.
■ EMERGENCY STOP push button:
Stops the machine immediately in an emergency situation. The motor remains stopped. The
pressure system is vented.
■ Safety relief valve:
Protects the system against excessive pressure. It is factory set.
■ Resistance thermometer:
Monitoring the airend discharge temperature protects the compressed air system from imper‐
missible temperature rises.
■ Pressure monitor:
Protects the refrigerant circuit of the refrigerated dryer against excessive pressure. It cannot be
set.
■ Enclosures and guards for moving parts and electrical connections:
Protect against accidental contact.
4.2.3 Floating relay contacts

Floating relay contacts are provided for the transfer of signals and messages.
Information on location, loading capacity and type of message or signal is found in the electrical
diagram.
If the floating relay contacts are connected to an external voltage source, voltage may be
present even when the machine is isolated from the power supply.

36 CSD 100/125 T 901726 08 USE
4.3 Operating panel SIGMA CONTROL 2

Keys
Fig. 7 Keys - overview
Position Name Function

1 «OFF» Switches the machine off.
2 «ON» Switches the machine on.
3 «Escape» Returns to the next higher menu option level.
Exits the edit mode without saving.
4 «Enter» Jumps to the selected menu option.
Exits the edit mode and saves.
5 «Down» Scrolls down the menu options.
Reduces a parameter value.
6 «Right» Jumps to the right.
Moves the cursor position to the next right field.
7 «Left» Jumps to the left.
Moves the cursor position to the next left field.
8 «Up» Scrolls up the menu options.
Increases a parameter value.
9 «Events and information» Operating mode:
Displays the event memory.
10 «Acknowledgement» Acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
11 «LOAD/IDLE» Toggles between the LOAD and IDLE operating modes.
12 «Remote control» Switches the remote control on and off.

901726 08 USE CSD 100/125 T 37

13 «Shift clock» Switches clock control on and off.
Tab. 44 Keys
Indicators
Fig. 8 Indicators – overview

14 Indicator field or dis‐ Graphic display with 8 lines and 30 characters per line.
play
15 Fault Flashes red when an alarm occurs.
Lights continuously when acknowledged.
16 Communication Continuous red light to indicate a faulty communication connec‐
tion, or an external fault message without machine shut-down.
17 Warning Flashes yellow for the following events:
■ Maintenance work due
■ Warning message
Continuous yellow light after acknowledgement.

18 Control voltage Continuous green light when voltage is applied to the controller.
19 LOAD Continuous green light when the machine is running in LOAD.
20 IDLE Continuous green light when the machine is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
21 Remote control Continuous green light when the machine is in remote control.
22 Shift clock Continuous green light when the machine is controlled by the tim‐
er (clock).

38 CSD 100/125 T 901726 08 USE
4.4 Operating modes and control modes

23 ON Continuous green light when the machine switched on.
Tab. 45 Indicators
RFID sensor field
RFID is the abbreviation for “Radio Frequency Identification” and enables the identification of per‐
sons or objects.
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐
vate the communication between transponder and SIGMA CONTROL 2.
A suitable transponder is the KAESER RFID EQUIPMENT CARD. Two of them have been provi‐
ded with the machine.
Typical application:
■ Users log on to the machine.
(no manual input of the password required.)
Fig. 9 RFID sensor field

24 RFID RFID sensor field for the communication with a suitable RFID transponder
Tab. 46 RFID sensor field
Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐
ing manual.

4.4.1 Operating modes
STOP
The machine is connected to the power supply.

The Control voltage LED lights green.
The machine is switched off. The ON LED is extinguished.
READY
The machine has been activated with «ON»:

■ The ON LED lights green.

901726 08 USE CSD 100/125 T 39
■ The drive motor is stopped.

■ The inlet valve is closed.
■ The minimum pressure/check valve shuts off the oil separator from the air distribution network.
■ The venting valve is open.
The compressor motor starts as soon as system pressure is lower than the set point pressure (cut-
off pressure).
In addition, timing and/or remote control may affect the start of the motor.
LOAD
The compressor motor runs under load.

■ The inlet valve is open.
■ The airend delivers compressed air to the distribution network.
IDLE
The compressor motor runs unloaded and draws little current.

■ The inlet valve is closed.
■ The minimum pressure/check valve isolates the oil separator tank from the air distribution net‐
work.
■ The venting valve is open.
A small volume of air circulates through the bleed hole in the inlet valve, through the airend and
back to the inlet valve via the venting line.
4.4.2 Control modes

Using the selected control mode, the controller switches the machine between its various opera‐
tional states in order to maintain the gauge working pressure between the set minimum and maxi‐
mum values, regardless of the drawn compressed air volume. The control mode also rules the de‐
gree of energy efficiency of the machine.
The shortest possible times for the various parameters is preset by the factory to ensure that the
compressor motor earlier and more frequently is at standstill. If you want to change these parame‐
ters, select the shortest possible times in order for the machine working energy-efficiently.
The machine-dependant venting time between the LOAD and READY operating modes ensures
load changes at minimum material stresses.
The following control modes can be set:

■ DUAL
■ QUADRO
■ VARIO
■ DYNAMIC
Supplementary mechanical flow rate regulation:

Option C1 ■ MODULATING control

40 CSD 100/125 T 901726 08 USE
Energy-efficient control modes for various applications:

Application Recommended control mode
Compressed air station with one machine or several machines VARIO
with comparable delivery
Machine for peak load in a compressed air station VARIO
Machine for intermediate load in a compressed air station DYNAMIC1)
Machine for basic load in a compressed air station DYNAMIC1)
1)
At exceedingly high pressure fluctuations or frequent drive motor starts (current peaks), switch
from DYNAMIC to VARIO.
Tab. 47 Energy-saving control modes
The VARIO control mode is factory preset, unless specifically ordered otherwise.
DUAL
In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain the machine working pressure between the preset minimum and maximum values. When
maximum pressure is reached, the machine switches to IDLE. When the preset idling time has
elapsed, the machine switches to READY.
QUADRO
Unlike the DUAL mode, the machine will switch in QUADRO after short periods between LOAD to
READY after being in IDLE.
After periods with a high compressed air consumption, the machine will switch from LOAD to
READY after being in IDLE.
In this event, the controller considers the time in READY mode as standstill time. The time in LOAD
and IDLE operating modes are taken as minimum runtime.
VARIO
The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idling
time is automatically lengthened or shortened to compensate for higher or lower machine starting
frequencies.
DYNAMIC
Unlike the DUAL regulating mode, the machine will switch from LOAD to READY in DYNAMIC
mode at low drive motor temperature.
At higher motor temperatures, the machine switches to IDLE until the compressor motor has
cooled down enough. Subsequently, the machine to READY.
The lower the drive motor temperature, the sooner (and, therefore, more often and longer) it is
stopped.
Option C1 MODULATING control
The MODULATING control is an additional mechanical regulation. It continuously changes the flow
rate within the machine's control range.
A control valve, the proportional controller, changes the degree of opening of the inlet valve when
the machine transports compressed air into the air network (LOAD)

901726 08 USE CSD 100/125 T 41
4.5 Refrigerated Dryer Control Modes
The load and power consumption of the drive motor rises and falls with the air demand.
4.5 Refrigerated Dryer Control Modes

The controller can operate in the following modes:
■ CONTINUOUS
■ TIMER
CONTINUOUS
The refrigerated dryer will remain activated even when the machine is in standby.
This mode of control is set up at the factory.
TIMER
The refrigerated dryer is switched on and off by a timer when the machine is in standby. In this
mode, the operating temperature is held within tight limits.
Which control mode is the most practical, and when?
Control mode Advantage Disadvantage

CONTINUOUS Constant dew point. Higher power consumption when the machine
is in standby mode.
TIMER Lower power consumption when Brief increase in dew point when the compres‐
the machine is in standby mode. sor re-starts
Tab. 48 Refrigerated dryer control modes
4.6 Options
The options available for your machine are described below.
4.6.1 Option C3
Controller SIGMA CONTROL 2: Connection to control technology
Connection to various control technology systems is possible.
SIGMA CONTROL 2
Main Control System (MCS):
■ Slot for a communication module to connect to a control technology system.
Input-Output-Module (IOM):
■ Module with digital and analogue inputs and outputs.
Tab. 49 Components
4.6.2 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.

42 CSD 100/125 T 901726 08 USE
4.6 Options
Fig. 10 Machine mountings
4.6.3 Option K2/K9

Water cooling
Stainless steel plate-type heat exchanger (Option K2) or bundled pipe heat exchangers (Option
K9) are used in machines with water cooling.
Option K2
Fig. 11 Water-cooling (Option K2)

1 Oil cooler 3 Cyclone separator
2 Compressed air cooler 4 Condensate drain
Option K9
Fig. 12 Water cooling (Option K9)

1 Oil cooler 3 Cyclone separator
2 Compressed air cooler 4 Condensate drain

901726 08 USE CSD 100/125 T 43
4.6 Options
4.6.4 Option K3
Cooling air filter mat
The mat filters the cooling air and keeps the cooler surface clean.
Fig. 13 Cooling air filter mat (option K3)

1 Cooling air filter mat
4.6.5 Option W2/W3

Heat recovery
The cooling oil circuit includes 2 valves influencing the cooling oil temperature:
■ Oil regulating valve: The machine's oil temperature regulator
■ Thermostatic valve: The heat recovery system's oil temperature regulator
The oil temperature regulators ensure that the cooling oil is kept at the ideal temperature for ma‐
chine operation.
The thermostatic valve opens first so that surplus heat is released into the heat recovery system. If
the heat recovery system cannot remove sufficient heat, the oil temperature regulator of the ma‐
chine opens to additionally release the cooling circuit via the oil cooler.
The heat available for recovery depends on the individual operating conditions of the machine.
If the heat recovery system is activated, the air discharge temperature is usually higher than in ma‐
chines without heat recovery, reducing the efficiency of the compressed air generation.
➤ Activate the heat recovery only if you can use the machine's waste heat.
See the user manual of the SIGMA CONTROL 2 for information regarding the activation and
deactivation of the heat recovery.
A plate-type heat exchanger is installed for heat recovery.
The plate-type heat exchanger transfers heat from the cooling oil to a heat-receiving medium.

44 CSD 100/125 T 901726 08 USE
4.6 Options
Fig. 14 Function of the heat recovery

1 Plate-type heat exchanger

901726 08 USE CSD 100/125 T 45
5.1 Ensuring safety

5.1 Ensuring safety
The conditions in which the machine is installed and operated have a decisive effect on safety.
Warning instructions are located before a potentially dangerous task.
Disregard of warning instructions can cause serious injuries!
Complying with safety warnings
Disregard of safety warnings can cause unforeseeable dangers!

➤ Strictly forbid fire, open flame and smoking.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapors or parts of the machine.
➤ Do not store inflammable material in the vicinity of the machine.
➤ The machine is not explosion-proof!
Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
comfortably and safely.
➤ Ensure that required ambient conditions are maintained.
Required ambient conditions may be:

■ Maintain ambient temperature and humidity
■ Ensure the appropriate composition of the air within the machine room:
─ Clean with no damaging contaminants (e.g., dust, fibers, fine sand).
─ Free of explosive or chemically unstable gases or vapors.
─ Free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sul‐
fide.
5.2 Installation conditions

5.2.1 Determining location and clearances
The machine is intended for installation in an appropriate machine room. Information on distances
from walls and ventilation is given below.
The distances quoted are recommended distances and ensure unhindered access to all ma‐
chine parts.
➤ Please consult an authorized KAESER SERVICE representative if you cannot comply
with these recommendations.
Precondition The floor must be level, firm and capable of bearing the weight of the machine.

46 CSD 100/125 T 901726 08 USE
5.2 Installation conditions
Fig. 15 Recommended machine placement and dimensions [in.]

A Exhaust fan
B Exhaust air duct
Z Inlet air opening
1. Ambient temperature too low.

Frozen condensate and highly viscous cooling oil can cause damage when starting the ma‐
chine.
➤ Make sure that the temperature of the machine is at least 37°F before starting.
➤ Heat the machine room adequately or install an auxiliary heater.
2. Ensure adequate lighting so that all work on the machine can be carried out without danger or
hindrance.
3. Ensure that the indicators can be read without glare and that the controller display cannot be
damaged by direct sunlight (UV radiation).
4. Ensure that all intake and exhaust apertures of the enclosure remain opened.
5. If installed outdoors, the machine must be protected from frost, direct sunlight, dust and rain.
5.2.2 Ensuring adequate ventilation

Adequate ventilation of the machine room has several tasks:
■ It prevents subatmospheric pressure in the machine room.
■ It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐
tions.
➤ Consult with KAESER SERVICE if you cannot ensure the conditions for an adequate
ventilation of the machine room.
1. Ensure that the volume of air flowing into the machine room is at least equivalent to that being
removed from it by the machine and exhaust fan.
2. Make sure that the machine and exhaust fan can only operate when the inlet aperture is ac‐
tually open.
3. Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the room.
4. Ensure clean air in order to support the proper functioning of the machine.

901726 08 USE CSD 100/125 T 47
5.3 Operating the machine in a compressed air network
5.2.3 Exhaust duct design

At the cooling air inlet and exhaust, the machine can only overcome the air resistance resulting
from the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐
ing.
➤ Consult an authorized KAESER SERVICE representative before deciding on:
■ Design of the exhaust air ducting
■ Transition between the machine and the exhaust air duct
■ Length of the ducting
■ Number of duct bends
■ Design of flaps or shutters
Further information Further information on the design of exhaust air ducts can be found in chapter 13.3.
5.3 Operating the machine in a compressed air network

If the machine is supplying an air network, the network working pressure may not exceed 232 psig.
Initial charging of a fully vented air system creates a very high rate of airflow through the air treat‐
ment devices. These conditions are detrimental to correct air treatment. Air quality suffers. To en‐
sure the desired air quality when charging a vented air network, we recommend the installation of
an air main charging system.
➤ Consult KAESER for advice on this subject.

48 CSD 100/125 T 901726 08 USE
6 Installation
6.1 Ensuring safety
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.
Complying with safety notes
Disregard of safety notes can cause unforeseeable dangers!

➤ Follow the instructions in chapter 3 'Safety and Responsibility'.
➤ Installation work may only be carried out by authorized personnel.
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.
When working on live components
➤ Work on electrical equipment may only be carried out by authorized electricians.
When working on the compressed air system
or death. The following safety concerns relate to any work on components that could be under
pressure.
➤ Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 psig.
When working on the drive system
in serious injury.
Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.

901726 08 USE CSD 100/125 T 49
6 Installation
6.2 Reporting Transport Damage
6.2 Reporting Transport Damage

1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.
6.3 Connecting the machine with the compressed air network

Condensate in the compressed air network can damage the piping:
➤ Install only corrosion-resistant pipes.
➤ Use fluoroelastomers as sealing material for seals.
➤ Note the electro-chemical voltage sequence.
➤ Consult with KAESER for suitable materials for the compressed air network.
Precondition The compressed air system is vented completely to atmospheric pressure.
Fig. 16 Compressed air piping

1 Compensator or flexible hose
2 Shut-off valve
➤ Do not induce any forces into the machine for which the compressive forces must be bal‐
anced by bracing.
1. Serious injury or death can result from loosening or opening components under
pressure.
2. A shut-off valve must be installed by the user in the connection line.
3. Connect the machine to the compressed air network with a flexible hose or appropriate com‐
pensator.
Further information The dimensional drawing in chapter 13.3 provides the size and position of the connection ports.
6.4 Connecting the condensate drain

A threaded hose connection is provided to attach a condensate drain hose.
The condensate must be able to drain freely.
➤ Only machines with 232 psig maximum permissible working pressure may be connected
to the condensate collecting line.

50 CSD 100/125 T 901726 08 USE
6 Installation
6.4 Connecting the condensate drain
Fig. 17 illustrates the recommended installation.

Condensate flows downward in the collecting line. This prevents condensate flowing back to the
compressor.
If condensate flows at several points into the condensate collecting line, you must install shut-off
valves in the condensate lines to shut the condensate line off before commencing maintenance
work.
Condensate line
Feature Value
Max. length1) [ft] 50
Max. delivery head [ft] 16
Material Copper
(pressure-resistant, cor‐ Stainless steel
rosion-proof)
Plastics
Hose line
1)
For longer lengths, please contact KAESER before installation.
Tab. 50 Condensate line
Condensate collecting line
Feature Value
Gradient [%] >1
Max. length1) [ft] 65
Material Copper
(pressure-resistant, cor‐ Stainless steel
rosion-proof)
Plastics
Hose line
1)
For longer lengths, please contact KAESER before installation.
Tab. 51 Condensate collecting line
Compressed air flow Line diameter ["]

rate1) [cfm]
<350 3/4
350 – 730 1
731 – 1410 1 1/2
>1410 2
1)
Compressed air flow rate as guide for the condensate volume to be expected
Tab. 52 Condensate collecting line: Line diameter

901726 08 USE CSD 100/125 T 51
6 Installation
6.5 Connecting the external pressure transducer
Connecting the condensate drain
Fig. 17 Connecting the condensate drain

1 Threaded connection 5 Shut-off valve
2 Condensate line A Delivery head
3 Condensate collecting line B Length of the condensate collecting line
4 Screw plug
Depending on the machine model, you may have several condensate drains.
➤ Directly connect every condensate drain to the condensate collecting line.
➤ Collect the condensate in a suitable container and dispose of in accordance with environ‐
mental regulations.
Further information The dimensional drawing in chapter 13.3 provides the size and position of the connection port.
6.5 Connecting the external pressure transducer

Material Retrofit kit: "External pressure transducer SIGMA CONTROL 2"
Use suitable shielded, copper-core cable (e.g.: LIYCY 2 x0.75 mm2 for ambient temperature up to
30°C and laying method C).
Precondition The power supply disconnecting device is switched off,

the device is locked off,
the absence of any voltage has been verified.
Cable length between the machine and the pressure transducer: < 98 ft.
By means of a pressure transducer, the pressure in the compressed air network can be measured
at any selected location and this signal used to regulate the compressor.
This ensures optimum compressor regulation with regard to the network pressure at the selected
location.
Safety monitoring of the machine's internal pressure is unaffected.
An authorized KAESER SERVICE representative will be glad to provide support on planning
and executing an individual solution.
1. Install the pressure transducer at the selected location in the compressed air network.

52 CSD 100/125 T 901726 08 USE
6 Installation
6.6 Refrigerated dryer: Connecting the transformer according to the power supply.
2. Using a suitable cable, connect the pressure transducer to a spare analog input.
➤ Connect as large an area of the shielding as possible to the mounting plate in the control
cabinet or use an EMC fitting to make contact.
3. When commissioning the machine with a SIGMA CONTROL 2, select the <Network actual
pressure> setting in the <AII> menu.
4. Select and activate the used analog input (AII).
Further information The electrical diagram in chapter 13.4 contains further details of the pressure transducer connec‐
tion.
6.6 Option T2
Refrigerated dryer: Connecting the transformer according to the
power supply.
The refrigerated dryer transformer has tappings for various power supply voltages.
1. Check that the correct connections are made for the supply voltage provided for the machine.
2. If necessary, re-connect the transformer to match the power supply voltage.
Further information The electrical diagram in chapter 13.4 contains further details of the power supply connection.
6.7 Connecting the machine with the power supply

The tolerance limits of the main voltage (power supply) must be within the permissible tolerance
limits of the rated voltage (machine).
1. The power supply must only be connected by authorized installation personnel or an author‐
ized electrician.
2. Carry out safety measures as stipulated in relevant regulations and in national accident pre‐
vention regulations. In addition, observe the regulations of the local electricity supplier.
3. Test the overcurrent protection cut-out (backup fuse) to ensure that the time it takes to discon‐
nect in response to a fault is within the permitted limit.
4. Select supply cable conductor cross-sections and fusing in accordance with local regulations.
5. The user must provide the machine with a lockable power supply disconnecting device.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
6. Check that the tappings on the control voltage transformer are connected according to the sup‐
ply voltage.
If not, change the tappings to suit the power supply voltage.
7. Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and check the absence of
any voltage.

901726 08 USE CSD 100/125 T 53
6 Installation
6.8 Options
8. Connect the machine to the power supply.

9. Ensure that the cabinet again complies with the requirements of degree of protection IP54.
Further information The electrical diagram in chapter 13.4 contains further details for the power supply connection.
6.8 Options
6.8.1 Option H1
Anchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.
Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.3.
6.8.2 Option K2/K9

Connecting the water cooling
➤ Take the electrochemical series into consideration and choose suitable materials for wa‐
ter connections.
➤ Keep the effect of pressure surge on the cooler as low as possible.
➤ Install an expansion tank to act as a pulsation dampener if pressure surges cannot be
avoided.
➤ Avoid a low inlet temperature for the cooling water as it can cause condensation. If re‐
quired, contact KAESER for suitable insulation measures.
Temperature-controlled cooling water supply systems, to which numerous machines are connec‐
ted, regulate water volumetric flow rate according to the difference in temperature between the
supply and the return water. Individual machines may not receive an adequate cooling water flow
rate with this system. Breakdowns are the result.
➤ KAESER can advise on how to ensure the cooling water supply via suitable control
valves.
Fig. 18 Connecting the water cooling

A Cooling water outlet 12 Connection port with plug
B Cooling water inlet 17 Safety relief valve
10 Shut-off valve

54 CSD 100/125 T 901726 08 USE
6 Installation
6.8 Options
1. The user is to provide the following fittings:

■ Dirt traps (grid size according to permissible particle size.
■ Shut-off valves 10 and connection ports 12 for maintenance and venting.
■ Safety relief valve 17 to prevent build-up of excessive pressure.
Actuating pressure and blow-off capacity of the safety valve are governed by the user's in‐
stallation design. The technical specification of the cooler must be taken into consideration.
2. Connect the cooling water lines to the fittings.
3. Open the shut-off valve on the cooling water outlet A .
4. Slowly open the cooling water inlet shut-off valve B to gradually fill the cooler with water.
5. Bleed air from the water lines.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connec‐
tion ports.
6.8.3 Option W2/W3

Connecting the heat recovery system
➤ Take the electrochemical series into consideration and choose suitable materials for con‐
nections.
➤ Keep the effect of pressure surges on the heat exchanger as low as possible.
➤ Install an expansion tank to act as a damper if pressure surges cannot be avoided.
➤ Install appropriate regulating devices if the heat transfer medium is to be kept constant.
➤ Avoid very low inlet temperatures of the heat transfer medium as it can cause condensa‐
tion. If required, contact KAESER for suitable insulation measures.
Cooling oil in the heat-receiving medium!

Oil may contaminate the medium if a leak occurs.
➤ Do not use the heat-receiving medium as drinking water.
Fig. 19 Connecting the heat recovery system

A Outlet 12 Connection port with plug
B Inlet 17 Safety relief valve
10 Shut-off valve

901726 08 USE CSD 100/125 T 55
6 Installation
6.8 Options
1. The user is to provide the following fittings:

■ Dirt trap with max. 0.1 mm strainer mesh
■ Shut-off valves 10 and connection ports 12 for maintenance and venting
■ Safety relief valve 17 to prevent build-up of excessive pressure.
Actuating pressure and blow-off capacity of the safety valve are governed by the user's in‐
stallation design. The technical specification of the heat exchanger must be taken into con‐
sideration.
2. Connect the supply lines and fittings.
3. Open the shut-off valve 10 at the inlet A .
4. Slowly open the shut-off valve 10 at the inlet B to gradually fill the heat exchanger with the
heat transfer medium.
5. Bleed the lines.
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size, and position of the connec‐
tion ports.

56 CSD 100/125 T 901726 08 USE
7 Initial Start-up
7.1 Ensuring safety
7 Initial Start-up
7.1 Ensuring safety
Here you will find instructions for a safe commissioning of the machine.

➤ Follow the instructions in chapter 3 'Safety and Responsibility'.
➤ Commissioning tasks may only be carried out by authorized personnel!
➤ Make sure that no one is working on the machine.
➤ Ensure that all service doors and panels are locked.
pressure.
in serious injury.


901726 08 USE CSD 100/125 T 57
7 Initial Start-up
7.2 Instructions to be observed before commissioning or re-commissioning
7.2 Instructions to be observed before commissioning or re-commis‐

sioning
Incorrect or improper commissioning can cause injury to persons and damage to the machine.
➤ Commissioning may only be carried out by authorized installation and service personnel who
have been trained on this machine.
Special measures for re-commissioning after storage
Storage period Remedy

longer than:
3 months ➤ Manually fill the airend with cooling oil.
12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Have the motor bearings checked by an authorized KAESER service repre‐
sentative.
36 months ➤ Have the overall technical condition checked by an authorized
KAESER service representative.
Tab. 53 Re-commissioning after storage
7.3 Checking installation and operating conditions

➤ Check and confirm all the items in the checklist before starting the machine.
To be checked See Confirmed?

chapter
➤ Are the operators completely familiar with safety regulations? –
➤ Have all the positioning conditions been fulfilled? 5
➤ Is a user's lockable power supply disconnecting device installed? 6.7
➤ Are the tolerance limits of the main voltage (power supply) within the 13.4
permissible tolerance limits of the nominal voltage (machine)?
(See nameplate in the control cabinet)
➤ Are the power supply cable conductor cross-sections and fuse rat‐ 2.14
ings adequate?
➤ Is the drive motor overload protection switch set according to the 7.4
power supply voltage?
➤ Is there fan motor overload protection switch set according to the 7.5
power supply voltage?
➤ Option T2: Check that the correct connections are made for the sup‐ 6.6
ply voltage provided for the machine.
➤ Have all electrical connections been checked for tightness? –
➤ Has the connection to the air system been made with a shut-off valve 6.3
and a hose or compensator?
➤ Is the condensate drain connected? 6.4

58 CSD 100/125 T 901726 08 USE
7 Initial Start-up
7.4 Setting the overload protection relay
To be checked See Confirmed?

chapter
➤ Is there sufficient cooling oil in the separator tank? 10.14
(oil level indicator outside the red zone)
➤ Is there sufficient cooling oil in the airend? 7.6
➤ Is the machine firmly anchored to the floor? 6.8.1
(Option H1)
➤ Is the supply of cooling water ensured? 6.8.2
(Option K2/K9)
➤ Are all access doors closed and latched and removable panels in –
place and secured?
Tab. 54 Installation conditions checklist
7.4 Setting the overload protection relay

Electrical diagram 13.4 gives the location of the overload protection relay.
With star-delta starting, the phase current is fed via the overload protection relay. This phase cur‐
rent is 0.58-times the rated motor current.
To prevent the overload protection relay from being triggered by voltage fluctuations, temperature
influences or component tolerances, the setting can be higher than the arithmetical phase current.
➤ Check the overload protection relay setting.
The overload protection relay shuts the machine down despite being correctly set?
➤ Contact an authorized KAESER service representative.
7.5 Setting the motor overload protection relay

Electrical diagram in chapter 13.4 gives the setting values for the motor overload protection switch.
In direct on-line starting, the current for the fan motor is fed via the motor overload protection relay.
To prevent the motor overload protection relay from being triggered by voltage fluctuations,
temperature influences or component tolerances, the setting can be higher than the rated
motor current.
➤ Check the motor overload protection relay setting.
The overload protection relay shuts the machine down despite being correctly set?
➤ Contact an authorized KAESER SERVICE representative.
7.6 Filling cooling oil into the airend

Before starting the compressor for the very first time and before re-starting after a shutdown period
of more than 3 months it is necessary to manually add a quantity of cooling oil into the airend. In
order to avoid that the cooling oil exceeds the permissible level, drain the required quantity from
the de-pressurized oil separator tank.
Chapter 10.17 provides detailed information on how to drain cooling oil from the oil separator tank.

901726 08 USE CSD 100/125 T 59
7 Initial Start-up
7.6 Filling cooling oil into the airend
Material 2.1 quart cooling oil from separator tank
Precondition The supply disconnecting device is switched off,

the absence of voltage has been verified.
The machine is fully vented, the pressure gauge on the oil separator tank reads 0 psig.
Fig. 20 Inlet valve filling port

1 Screw plug
2 Inlet valve
1. Unscrew the filler plug from the inlet valve.

2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug.
Fig. 21 Coupling
1 Airend 3 Safety screen
2 Coupling 4 Arrow showing direction of rotation
1. Remove the safety screen 3 .

2. Turn the airend 4 by turning the coupling 1 by hand in the direction indicated by the arrow 2 .
3. Replace the safety screen 3 .

60 CSD 100/125 T 901726 08 USE
7 Initial Start-up
7.7 Activating and deactivating the MODULATING control
7.7 Option C1
Activating and deactivating the MODULATING control
Use a shut-off valve to activate and deactivate the MODULATING control. If the MODULATING
control is deactivated, the machine always delivers the maximum possible flow rate in LOAD mode.
MODULATING control Shut-off valve

Switch on Open
Switch off Close
Tab. 55 MODULATING control: Setting the shut-off valve

Fig. 22 MODULATING control: Setting the shut-off valve

1 Control valve (proportional control)
2 Shut-off valve
➤ Open or close the shut-off valve, depending on the required control mode.
The regulating valve is factory set. Consult with KAESER SERVICE before changing.
7.8 Starting the machine for the first time

Precondition No personnel is working on the machine.
All access doors are closed.
All removable panels are in place and secured.
1. Open the shut-off valve to the air network.

2. Switch on the power supply disconnecting device.
After the controller has carried out a self-test, the green Controller on LED is lit continuously.
3. If required:
Change the display language as described in chapter 7.10.

901726 08 USE CSD 100/125 T 61
7 Initial Start-up
7.9 Setting the setpoint pressure
4. Press the «ON» key.

The compressor motor runs up and after a short time the machine switches to LOAD and deliv‐
ers compressed air.
➤ Watch for any faults occurring in the first hours of operation.
➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.
Does the machine stop when the compressor motor rotates in the wrong direction?
➤ Switch off and lock out the power supply disconnecting device, and verify the absence of
voltage.
➤ Changeover phase lines L1 and L2.
➤ Acknowledge any existing alarm messages and switch the machine on again.
7.9 Setting the setpoint pressure

The system pressure pA is factory set to the highest possible value.
Adjustment is necessary for individual operating conditions.
Do not set the setpoint pressure of the machine higher than the maximum working pressure
of the whole compressed air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To reduce the cycling (toggling) frequency:
➤ Increase the difference between cut-in and cut-out pressure.
➤ Add a larger air receiver downstream to increase buffer capacity.
➤ Set the setpoint pressure as described in the SIGMA CONTROL 2 operating manual.
7.10 Setting the display language

The controller can display text messages in several languages.
You can set the language for texts on the display. This setting will be retained even when the ma‐
chine is switched off.
1. In operating mode, switch to the main menu with the «Return» key.
2. Press the «UP» or «DOWN» keys until the current language is shown as active line (inverse):
88 psig 176 ° F
–––––––– de_DE Deutsch –––––––– Current language (active line)
▶1 xxxxxxxxxx Submenu
3. Use the «Return» key to switch to setting mode.

The language display flashes.
4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with the «Enter» key.

62 CSD 100/125 T 901726 08 USE
7 Initial Start-up
7.10 Setting the display language
Result The display texts are now in the selected language.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.

901726 08 USE CSD 100/125 T 63
8 Operation
8.1 Switching on and off
8 Operation
8.1 Switching on and off
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device should be installed by the user.
Fig. 23 Switching on and off

1 Machine ON LED 11 «LOAD/IDLE» toggle key
2 «ON» key 19 LOAD LED
3 «OFF» key 20 IDLE LED
8 Controller voltage LED
8.1.1 Switching on
Precondition No personnel are working on the machine.
All access doors and panels are closed and secure.
1. Switch on the power supply disconnecting device.

The Controller voltage LED lights green.
2. Press the «ON» key.
The ON LED lights green.
If a power failure occurs, the machine is not prevented from restarting automatically when
power is resumed.
It can restart automatically as soon as power is restored.
Result The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut-
off pressure).
8.1.2 Switching off

1. Press the «OFF» key.
The machine switches to IDLE and the IDLE LED flashes. The SIGMA CONTROL 2 displays
Stopping. The ON LED extinguishes as soon as the automatic shut-off action is completed.
2. Switch off and lock out the power supply disconnecting device.

64 CSD 100/125 T 901726 08 USE
8 Operation
8.2 Switching off in an emergency and switching on again
Result The Controller voltage LED extinguishes. The machine is switched off and disconnected from the
power supply.
In rare cases, if you need to shut the machine down immediately and cannot wait until the
automatic shut-down process is finished:
➤ Press «OFF» once again.
8.2 Switching off in an emergency and switching on again

The EMERGENCY STOP push button is located below the control panel.
Fig. 24 Switching off in an emergency

9 EMERGENCY STOP push button
Switching off
➤ Press the EMERGENCY STOP push button.
Result The EMERGENCY STOP push button remains latched after actuation.
The compressor's pressure system is vented and the machine is prevented from automatically re-
starting.
Switching on
Precondition The fault has been rectified
1. Turn the EMERGENCY STOP push button in the direction of the arrow to unlatch it.
2. Acknowledge any existing alarm messages.
Result The machine can now be started again.
8.3 Switching on and off from a remote control center

Precondition A link to the remote control center exists.

901726 08 USE CSD 100/125 T 65
8 Operation
8.4 Using the timer for switching on and off
Fig. 25 Switching on and off from a remote control center

1 «Remote control» key
2 Remote control LED
1. Attach an easily seen notice to the machine that warns of remote operation.
Remote control: Risk of injury caused by unexpected starting!

➤ Make sure that the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 56 Machine identification
2. Label the starting device in the remote control center as follows:
Remote control: Risk of injury caused by unexpected starting!

➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 57 Remote control center identification
3. Press the «Remote control» key.

The Remote control LED lights. The machine can be remotely controlled.
8.4 Using the timer for switching on and off

Precondition The clock is programmed.

66 CSD 100/125 T 901726 08 USE
8 Operation
8.5 Interpreting operation messages
Fig. 26 Using the timer for switching on and off

1 «Timer» key
2 Timer LED
1. Attach an easily seen notice to the machine that warns of time-controlled operation:
Timer control: Risk of injury caused by unexpected starting!

➤ Make sure that the power supply disconnecting device is switched off before commencing any
work on the machine.
Tab. 58 Machine identification
2. Press the «Timer» key.

The Timer LED lights. The timer switches the machine on and off.
8.5 Interpreting operation messages

The controller will automatically display operation messages informing you about the current opera‐
tional state of the machine.
Operating messages are identified with the letter O.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.
8.6 Acknowledging alarm and warning messages

Messages are displayed on the "new value" principle:
■ Message coming: LED flashes
■ Message acknowledged: LED illuminates
■ Message going: LED off
or
■ Message coming: LED flashes

■ Message going: LED flashes
■ Message acknowledged: LED off

901726 08 USE CSD 100/125 T 67
8 Operation
8.6 Acknowledging alarm and warning messages
Fig. 27 Acknowledging messages

10 LED Warning (yellow)
11 LED Alarm (red)
12 Key «Acknowledge»
Alarm message
An alarm shuts the machine down automatically. The red alarm LED flashes.
The system displays the appropriate message.
Precondition The fault has been rectified.
➤ Acknowledge the message with the «acknowledge» key.

The Fault LED extinguishes.
The machine is again ready for operation.
If the machine was switched off with the EMERGENCY STOP button:
➤ Unlatch the EMERGENCY STOP button (turn in direction of the arrow) before acknowl‐
edging the alarm message.
Further information Please refer to the SIGMA CONTROL 2 operating manual for a list of possible fault messages dur‐
ing operation.
Warning message
If maintenance work is to be carried out or if a warning is displayed before an alarm, the yel‐
low warning LED flashes.
The system displays the appropriate message.
Precondition The danger of an alarm is passed,

maintenance has been carried out.
➤ Acknowledge the message with the «Acknowledge» key.

The warning LED extinguishes.
Further information A list of possible alarm messages occurring during operation can be found in the service manual
SIGMA CONTROL 2 .

68 CSD 100/125 T 901726 08 USE

There are 3 types of fault:
■ Warning:
─ Warning messagesW
■ Fault (with indication):
─ Alarm messagesA
─ System messages Y
─ Diagnostic messages D
■ Other faults (without indication): See chapter 9.2
The messages valid for your machine are dependent on how the individual machine is equipped.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorized KAESER SERVICE representative.
Further information Detailed information for the various messages can be found in the user manual
SIGMA CONTROL 2.
9.2 Other faults

Fault Possible cause Remedy
Machine runs but produces no Inlet valve not opening or only Call an authorized
compressed air. opening partially. KAESER SERVICE representa‐
tive.
Venting valve not closing. Call an authorized
KAESER SERVICE representa‐
tive.
Leaks in the pressure system. Check pipework and connec‐
tions for leaks and tighten any
loose connections.
Air demand is greater than the Check the air system for leaks.
capacity of the compressor. Shut down consumer(s).
Hose coupling or maintenance Remove coupling or mainte‐
hose still plugged into the nance hose.
quick-release coupling on the
oil separator tank.
Cooling oil runs out of the in‐ Oil level in the oil separator Drain off oil until the correct lev‐
take filter. tank too high. el is reached.
Inlet valve defective. Call an authorized
tive.

901726 08 USE CSD 100/125 T 69
9.2 Other faults
Fault Possible cause Remedy

Compressor switches be‐ Receiver too small. Increase size of receiver.
tween LOAD and IDLE more Airflow into the compressed air Increase air pipe diameters.
than twice per minute. network restricted. Check filter elements.
The differential between cut-in Check switching differential.
and cut-out pressure too is
small.
Cooling oil leaking into the ma‐ Hose coupling or maintenance Remove coupling or mainte‐
chine interior. hose still plugged into the nance hose.
quick-release coupling on the
oil separator tank.
Oil cooler leaking. Call an authorized
tive.
Leaking pipe joints. Tighten pipe joints.
Replace seals.
Cooling oil consumption too Unsuitable oil is being used. Change to SIGMA FLUID cool‐
high. ing oil.
Oil separator cartridge split. Change the oil separator car‐
tridge.
Oil level in the oil separator Drain off oil until the correct lev‐
tank too high. el is reached.
Oil return line dirty. Check the dirt trap strainer in
the oil return line.
Tab. 59 Other faults and remedies

70 CSD 100/125 T 901726 08 USE
10 Maintenance
10.1 Ensuring safety
10 Maintenance
10.1 Ensuring safety
Follow the instructions below to ensure safe machine maintenance.

➤ Follow the instructions in chapter 3 “Safety and Responsibility”.
➤ Maintenance work may only be carried out by authorized personnel.
➤ Use the safety sign below to advise others that the machine is currently being serviced:
Sign Meaning
Serious injury or death can result from activating the machine during service!
➤ Do not activate the machine.
Tab. 60 Warn others that the machine is being serviced.
➤ Before switching on, make sure that nobody is working on the machine and all access doors
and panels are closed and locked.
Touching voltage-carrying components can result in electric shocks, burns, or death.

➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
pressure.
Touching voltage-carrying components can result in electric shocks, burns, or death.

901726 08 USE CSD 100/125 T 71
10 Maintenance
10.2 Following the maintenance plan
Touching the fan wheel, the coupling, or the drive while the machine is switched on can result in
serious injury.
➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.


10.2.1 Logging maintenance work
The maintenance intervals given are those recommended for KAESER original components
with average operating conditions.
➤ In adverse conditions, perform maintenance work at shorter intervals.
Adverse conditions are, e.g.:

■ high temperatures
■ much dust
■ high number of load changes
■ low load
➤ Adjust the maintenance intervals with regard to local installation and operating condi‐
tions.
➤ Document all maintenance and service work.
This enables the frequency of individual maintenance tasks and deviations from our recom‐
mendations to be determined.
Further information A prepared list is provided in chapter 10.22.
10.2.2 Resetting maintenance interval counters

According to the way a machine is equipped, sensors and/or maintenance interval counters moni‐
tor the operational state of important functional devices. Required maintenance work is shown on
SIGMA CONTROL 2.
Precondition Maintenance performed and

maintenance message acknowledged.
➤ Reset the maintenance interval counter as described in the SIGMA CONTROL 2 operating
manual.
10.2.3 Regular maintenance tasks

The table below lists the required maintenance tasks.
The refrigeration circuit is a closed system. Repairs may only be carried out by certified personnel.

72 CSD 100/125 T 901726 08 USE
10 Maintenance
➤ Take note of the controller's service messages and carry out tasks punctually, taking ambient
and operating conditions into account:
Interval Maintenance task See chapter

Weekly Check the cooling oil level. 10.14
Control cabinet: 10.3
Check the filter mat.
Check the condensate drain. 10.21
Up to 1000 h Clean the cooler. 10.4
Option K3: 10.6
Check the filter mat.
Clean the refrigerant condenser. 10.20
Up to 3000 h Option K3: 10.6
Change the filter mat.
Control cabinet: 10.3
Change the filter mat.
Up to 6000 h Condensate drain: 10.21.2
At least every 2 years Change the Service Unit.
Display: Carry out air filter maintenance. 10.8

SIGMA CONTROL 2 Maintain the motor bearings. 10.9
Check the coupling. 10.10
Display: Change the oil filter. 10.18
SIGMA CONTROL 2
At least once a year
Display: Change the oil separator cartridge. 10.19
SIGMA CONTROL 2
At least every 3 years
Variable, see table 62 Change the cooling oil. 10.17
Annually Check the safety relief valve. 10.11
Check the function: 10.12
Safety shut-down due to excessive airend discharge tem‐
perature.
Check the EMERGENCY STOP push-button. 10.13
Have the pressure monitor checked by an authorized —
KAESER service representative.
Check the cooler for leaks. 10.4
Maintain the water-cooling. 10.5
Maintain the heat recovery system. 10.7
Check that all electrical connections are tight. —
h = operating hours
Tab. 61 Regular maintenance tasks

901726 08 USE CSD 100/125 T 73
10 Maintenance
10.2.4 Cooling oil changing interval

Machine utilization and ambient conditions are important criteria for the number and length of the
change intervals.
An authorized KAESER SERVICE representative will support you in determining appropriate
intervals and provide information on the possibilities of oil analysis.
➤ Please observe national regulations regarding the use of cooling oil in oil-injected screw com‐
pressors.
➤ Check operating conditions and adjust intervals as necessary.
KAESER LUBRICANTS
SIGMA Lubricant Description Maximum Recommended Change Interval
First oil change Subsequent oil change
M-460 ISO 46 Semi-Synthetic 2000 Hours 3000 Hours
Lubricant
S-460 ISO 46 Synthetic Lu‐ 6000 Hours 8000 Hours
bricant
S-680 ISO 68 Synthetic Lu‐ 6000 Hours 8000 Hours
bricant
FG-460 ISO 46 Food Grade 2000 Hours 3000 Hours
Synthetic Fluid
Tab. 62 Oil change intervals lubricants
10.2.5 Regular service tasks

The table below lists necessary service tasks.
➤ Only an authorized KAESER service representative should carry out service work.
➤ Have service tasks carried out punctually taking ambient and operating conditions into ac‐
count.
Interval Service task

Display: Valve maintenance.
SIGMA CONTROL 2 Compressor drive motor:
Replace the motor bearings.
Fan motor
Replace the motor bearings.
Up to 36000 h Have the plastic pipes and hose lines been replaced.
At least every 6 years
Up to 36000 h Replace the control cabinet fan.
At least every 20 years. Replace safety-relevant components of the safety functions.
h = operating hours
Tab. 63 Regular service tasks

74 CSD 100/125 T 901726 08 USE
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10.3 Control cabinet: Clean or renew the filter mat
10.3 Control cabinet: Clean or renew the filter mat

A filter mat is placed behind every ventilation grill. Filter mats protect the control cabinet from in‐
gress of dirt. If the filter mats are clogged, adequate cooling of the components is no longer ensur‐
ed. In such a case, clean or replace the filter mats.
Material Warm water and household detergent

Spare parts (as required)
Precondition The power supply isolating device is switched off,

The machine has cooled down.
Fig. 28 Switching cabinet ventilation

1 Ventilation grill
2 Filter mat
1. Carefully remove the ventilation grill and take out the filter mat.
2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm
water and household detergent.
3. Change the filter mat if cleaning is not possible or if the change interval has expired.
4. Insert the filter mat in the frame and latch in the ventilation grill.
10.4 Option K1
Cooler maintenance
Regularly clean the cooler. This ensures reliable cooling of the machine and the compressed air.
The frequency is mainly dependent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed air.
Clogged coolers are indicative of unfavorable ambient conditions. Such ambient conditions
clog the cooling air ducts in the machine's interior and the motors resulting in increased wear
and tear.
➤ Have the authorized KAESER service representative clean the cooling air ducts.

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10 Maintenance
10.5 Water-cooling Maintenance
Material Brush and vacuum cleaner

Face mask (as required)

Fig. 29 Clean cooler/radiator

1 Radiator
2 Brush
Cleaning the cooler/radiator
Do not use sharp objects to clean the cooler. It could be damaged.

Avoid creating clouds of dust.
➤ Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt.
The air and oil coolers can no longer be properly cleaned?
➤ Have severe clogging removed by an authorized KAESER service representative.
Checking the cooler for leaks
➤ Visual inspection: Did cooling oil escape?

Is a cooler leaking?
➤ Have the defective cooler repaired immediately by an authorized KAESER service repre‐
sentative.
10.5 Option K2/K9

Water-cooling Maintenance
Cooler clogging causes overheating and machine damage.
➤ Observe the airend discharge temperature to detect any tendency to rise.
Check the cooler regularly for leaks and contamination. Frequency of checking is dependant on the
characteristics of the cooling water.

76 CSD 100/125 T 901726 08 USE
10 Maintenance
10.6 Cleaning or Renewing the Cooling Air Filter Mat
Precondition The power supply disconnecting device is switched off.

The disconnecting device is locked in the off position.
A check has been made that no voltage is present.
Checking for leaks
Pressure in the cooling oil circuit is generally higher than that in the cooling water system. If a leak
occurs, oil will run into the cooling water.
1. Check the cooler visually for leaks.
2. Have an authorized KAESER service representative check the cooler for internal leaks at least
once a year.
Cleaning
➤ An authorized KAESER service representative should clean the cooler when the airend dis‐
charge temperature is 10 °C above the annual average.
10.6 Option K3
Cleaning or Renewing the Cooling Air Filter Mat
The filter mat helps to keep the cooler clean. If the filter mat is clogged, adequate cooling of the
components is no longer ensured.
Material Warm water and household detergent

Spare parts (as required)
Precondition The machine is switched off.
Fig. 30 Cooling air filter mat

1 Cooling air filter mat
2 Retaining frame
3 Fixing
Removal
1. Open the fixing 3

by turning 90° counter clockwise with a screwdriver.
2. Remove the frame 2 .

901726 08 USE CSD 100/125 T 77
10 Maintenance
10.7 Maintaining the heat recovery system
Cleaning
➤ Renew the mat if cleaning is not possible or has already been carried out 5 times.
➤ Beat the mat 1 or use a vacuum cleaner to remove loose dirt.

If necessary, wash the mat in lukewarm water (about 100 °F) and household detergent then
rinse thoroughly.
Refitting
➤ Replace the frame and close the fixings.

Use a screwdriver to turn the fixings 90° clockwise until they latch.
10.7 Option W2/W3

Maintaining the heat recovery system
Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is depend‐
ant on the characteristics of the heat transfer medium.
Pressure in the cooling oil circuit is generally higher than that in the heat recovery system. If a leak
occurs, oil will run into the heat-receiving medium. Increased cooling oil loss can indicate a leaking
heat exchanger.

the absence of voltage has been verified,
the machine has cooled down.
1. Check the heat exchanger visually for leaks.

2. Have an authorized KAESER service representative check the heat exchanger for internal
leaks and clean if contaminated.
10.8 Air filter maintenance

A pre-filter system is installed in order to increase the service life of the air filter cartridge.
When the 0013 or 0028 warning messages are displayed, you should clean the pre-filter (see
chapter 10.8.1). Cleaning of the pre-filter is permitted once only.
If the 0013 or 0028 warning messages are displayed again, you should replace the pre-filter
together with the air filter cartridge.

lockout and tagout the device,
verify the absence of any voltage.
➤ Clean the pre-filter (see chapter 10.8.1).

➤ Replace the pre-filter and the air filter cartridge (see chapter 10.8.2).

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10 Maintenance
10.8 Air filter maintenance
10.8.1 Cleaning the pre-filter

The pre-filter may be cleaned once only.
Material Warm water and mild household detergent
Fig. 31 Cleaning the pre-filter

1 Pre-filter
2 Air filter cartridge
3 Hook-and-loop tape
1. Remove the air filter cartridge 2 as described in chapter 10.8.2.

2. Remove the pre-filter 1 from the air filter element, rinse out with warm water and household
detergent, then leave to dry.
3. Wrap the pre-filter 1 around the air filter element 2 with printed side facing inwards.
The pre-filter must completely cover the air filter cartridge's filter material.
4. Fasten the pre-filter in place with hook and loop tape 3 .
5. Install the air filter cartridge 2 as described in chapter 10.8.2.
10.8.2 Cleaning or replacing the pre-filter and air filter cartridge

All sealing surfaces have been designed to match each other. The use of an unsuitable air
filter cartridge can permit dirt to enter the pressure system and cause damage to the ma‐
chine.
Do not clean the air filter cartridge. A damaged air filter cartridge can permit dirt to enter the
pressure system and cause damage to the machine.
Material Air filter cartridge

Pre-filter

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10 Maintenance
10.9 Motor maintenance
Fig. 32 Air filter maintenance

1 Screw
2 Air filter element
3 Cover
1. Undo the screws 1 and lift out the cover 3 .

2. Remove the old air filter element and dispose of in accordance with applicable environmental
protection regulations.
3. Clean all parts and sealing surfaces.
4. Wrap the new pre-filter around the air filter cartridge with the printed side facing inwards (see
Fig. 31).
The pre-filter must completely cover the filter material of the air filter cartridge.
5. Fasten the pre-filter in place with hook and loop tape.
6. Replace the filter element.
7. Insert the cover in the machine and secure with screws 1 .
8. Close all access doors and reinstall all enclosure panels.
9. Switch on the electrical power supply via the power supply device and reset the maintenance
interval counter.
10.9 Motor maintenance

In motors with bearings with re-greasing facility, the greasing nipples are located at the outside of
the machine. The grease lines are pre-filled with bearing grease.
Use only the high temperature grease UNIREX N3 for the motor bearings. Bearing damages
caused by the use of other brands of grease are excluded from the warranty.
Material Bearing grease: UNIREX N3

Cleaning cloths

80 CSD 100/125 T 901726 08 USE
10 Maintenance
10.10 Checking the Coupling
Fig. 33 Motor maintenance

1 Grease nipple (compressor drive motor)
2 Grease nipple fan motor
Compressor drive motor:
The required grease quantity is shown on the nameplate of the compressor drive motor.
Precondition Motor running
1. Clean the nipple with a cloth before greasing.

2. Grease both bearings with a grease gun.
3. Reset the maintenance interval counter.
Option K1 Fan motor
The required grease quantity is shown on the nameplate of the fan motor.
Precondition Motor running
1. Clean the nipple with a cloth before greasing.

2. Grease both bearings with a grease gun.
3. Reset the maintenance interval counter.
Option K2/K9 Fan motor
➤ Have the fan motor bearings checked by a KAESER service representative during regular
maintenance visits.
10.10 Checking the Coupling

A defective coupling is recognizable by:
■ noisy running,
■ surface cracks,
■ color change.
Danger of injury from rotating coupling!

➤ Never switch the machine on without the safety screen in place over the coupling.

901726 08 USE CSD 100/125 T 81
10 Maintenance
10.11 Testing the safety relief valve
Fig. 34 Checking the coupling

1 Safety screen
2 Coupling
Check for uneven or noisy running
Precondition The machine is running
➤ Check the coupling for noisy or uneven running.
Make a visual check for damage
Precondition The power supply disconnecting device is switched off.

The disconnecting device is locked in the off position.
A check has been made that no voltage is present.
1. Remove the securing screws and take off the safety screen.
2. Turn the coupling my hand and look for damage or color change.
3. Refit the safety screen.
4. Close all access doors and replace all enclosure panels.
Does the coupling have cracks or changes in color?
➤ Have a damaged coupling changed by an authorized KAESER SERVICE representative.
10.11 Testing the safety relief valve

In order to check the safety relief valve, the machine's working pressure is raised above the acti‐
vating pressure of the valve.
Blow off protection and air system pressure monitoring are switched off during the test. In normal
operation, the blow-off protection will switch off the machine before the safety relief valve responds.
During the inspection, the blow-off protection will switch off the machine only when the activating
pressure of the safety relief valve has been exceeded by 14.7 psig.

82 CSD 100/125 T 901726 08 USE
10 Maintenance
10.12 Checking the overheating safety shutdown function
➤ Follow the detailed description of this procedure in theSIGMA CONTROL 2 operating

manual
➤ Never operate the machine without a correctly functioning safety relief valve.
➤ Have a defective safety relief valve replaced immediately.
Excessive noise is caused when the safety relief valve blows off!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear hearing protection.
1. Close the user's shut-off valve between the machine and the air distribution network.
2. Read off the activating pressure on the valve.
(the activating pressure is usually to be found at the end of the part identification)
3. Log on to SIGMA CONTROL 2 with access level 2.
4. Observe the display of pressure on SIGMA CONTROL 2 and call up the test function.
5. Risk of burns due to released cooling oil and compressed air when blowing off
the safety relief valve!
➤ Close all access doors, replace and secure all removable panels.
➤ Wear eye protection.
6. End the test as soon as the safety relief valve blows off or working pressure exceeds the acti‐
vating pressure of the safety relief valve by nearly 14.7 psig.
7. If necessary, vent the machine and replace the defective safety relief valve.
8. Deactivate the test function
9. Open the user's shut-off valve between the machine and the air distribution network.
10.12 Checking the overheating safety shutdown function

The machine should shut down if the airend discharge temperature reaches a maximum of 230 °F.
➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐
ual.
The machine does not shut down?
➤ Have the safety shutdown function checked by an authorized KAESER SERVICE repre‐
sentative.

901726 08 USE CSD 100/125 T 83
10 Maintenance
10.13 Testing the EMERGENCY STOP push button
10.13 Testing the EMERGENCY STOP push button
Fig. 35 Testing the EMERGENCY STOP push button

9 EMERGENCY STOP push button
Precondition The compressor motor is running.
1. Press the EMERGENCY STOP push button.

The compressor motor stops, the pressure system is vented, and the machine is prevented
from automatically restarting.
The compressor motor does not stop?
The safety function of the EMERGENCY STOP push button is no longer ensured.
➤ Shut down the machine immediately and call an authorized KAESER SERVICE repre‐
sentative.
2. Turn the EMERGENCY STOP push button in the direction of the arrow to unlatch it.
3. Acknowledge the alarm message.
10.14 Checking the cooling oil level

In frequency-controlled compressors (SFC) the oil level indicator is only accurate when the
machine is running at or near maximum speed.
The lower the pressure at the compressed air outlet, the higher the speed.
SIGMA CONTROL 2 displays this value.
Precondition The machine has been running at least 5 minutes in LOAD mode.

84 CSD 100/125 T 901726 08 USE
10 Maintenance
10.15 Venting the machine (de-pressurizing)
Fig. 36 Checking the cooling oil level

1 Minimum oil level
2 Maximum oil level
3 Optimum oil level
1. Danger of burning - hot surfaces!

➤ Wear long-sleeved clothing and protective gloves.
2. Check the cooling oil level with machine running under LOAD.
Result As soon as the minimum level is reached: Replenish the cooling oil.

Venting takes place in three stages:
■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.
The machine must be isolated from the compressed air network and completely vented be‐
fore undertaking any work on the pressure system.
Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.

Escaping oil mist is damaging to health.

➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

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10 Maintenance
Fig. 37 Venting the machine

1 Hose coupling (air cooler venting) 7 Shut-off valve
2 Pressure gauge A Shut-off valve open
3 Hose coupling (oil separator tank venting) B Shut-off valve closed
6 Male hose fitting 8 Maintenance hose
Isolating the machine from the air system
➤ Close the user's shut-off valve between the machine and the air distribution network.
If no shut-off valve is provided by the user, the complete air network must be vented.
Venting the oil separator tank
The oil circulation vents automatically as soon as the machine is stopped.

➤ Check that the oil separator tank pressure gauge reads 0 psig.
The pressure gauge does not read 0 psig after automatic venting?
➤ Make sure that the shut-off valve is closed or that the complete air system is vented.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact
an authorized KAESER SERVICE representative.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the air system or the section from the shut-off valve to the minimum pres‐
sure/check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .

86 CSD 100/125 T 901726 08 USE
10 Maintenance
10.16 Replenishing the cooling oil

Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.

Fig. 38 Replenishing the cooling oil

1 Hose coupling (air cooler venting) 6 Male hose fitting
2 Pressure gauge 7 Shut-off valve
3 Hose coupling (oil separator tank venting) A Shut-off valve open
4 Oil filler port with plug B Shut-off valve closed
5 Cooling oil level indicator 8 Maintenance hose
1. Vent the machine as described in section 10.16.1.

2. Fill with cooling oil and test run as described in section 10.16.2.
10.16.1 Venting the machine (de-pressurizing)

Venting takes place in three stages:
■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.
Escaping oil mist is damaging to health.

➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

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10 Maintenance
Isolating the machine from the air system
➤ Close the user's shut-off valve between the machine and the air distribution network.
If no shut-off valve is provided by the user, the complete air network must be vented.
Venting the oil separator tank
The oil circulation vents automatically as soon as the machine is stopped.

➤ Check that the oil separator tank pressure gauge reads 0 psig.
The pressure gauge does not read 0 psig after automatic venting?
➤ Make sure that the shut-off valve is closed or that the complete air system is vented.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact
an authorized KAESER SERVICE representative.
Manually venting the air cooler
After shutting down the compressor and venting the oil separator tank, the machine is still un‐
der pressure from the air system or the section from the shut-off valve to the minimum pres‐
sure/check valve.
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .
10.16.2 Topping off with cooling oil and trial run

Replenishing the cooling oil
A sticker on the oil separator tank specifies the type of oil used.
1. Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy
is released suddenly.
2. The machine could be damaged by unsuitable oil!
➤ Never mix different types of oil.
➤ Never top off with a different type of oil than has already been used in the machine.
3. Slowly unscrew the filler plug 4 .
4. Top off to bring the oil to the correct level.
5. Renew the filler plug's gasket if necessary and screw the plug into the filler port.
Starting the machine and carrying out a trial run
1. Close all access doors, replace and secure all removable panels.

88 CSD 100/125 T 901726 08 USE
10 Maintenance
10.17 Changing the cooling oil
3. After approx. 10 minutes of operation: Check the cooling oil level and top off if necessary.
4. Switch off the machine and check visually for leaks.

Drain the oil completely from the following components:
■ Oil separator tank
■ Oil cooler
■ Airend
■ Heat exchanger (Option W2/W3)
➤ Always change the oil filter and oil separator cartridge when changing the oil.
➤ Contact an authorized KAESER service representative if condensate is detected in the
cooling oil. It is necessary to adjust the airend discharge temperature to suit operating
conditions.
Compressed air helps to expel the oil. This compressed air can be taken either from the compres‐
sor itself or from an external source.
An external source of compressed air is necessary in the following cases (examples):

■ The machine is not operational.
■ The machine is to be restarted after a long period of standstill.
Material Cooling oil

Cooling oil receptacle
The maintenance hose with hose coupling and shut-off valve is stowed beneath the oil separator
tank.
There is risk of burns from hot components and oil!


901726 08 USE CSD 100/125 T 89
10 Maintenance
Fig. 39 Changing the cooling oil, oil separator tank

1 Hose coupling (air cooler venting) A Shut-off valve (open)
2 Pressure gauge B Shut-off valve (closed)
3 Hose coupling (oil separator tank venting) 8 Maintenance hose
4 Oil filler port with plug 9 Hose coupling (oil drain)
5 Cooling oil level indicator 10 Shut-off valve (venting line)
6 Plug-in nozzle 11 Shut-off valve (oil drain)
7 Shut-off valve
Changing the oil using internal pressure Changing the oil with an external compressed
air source
Precondition: Precondition:
The machine has been running at least 5 mi‐ The power supply disconnecting device is
nutes in LOAD mode., switched off,
the machine is fully vented, the device is locked off,
the pressure gauge on the oil separator tank the absence of any voltage has been verified,
reads 0 psig. the machine is fully vented,
1. Close the shut-off valve 10 in the venting the pressure gauge on the oil separator tank
line. reads 0 psig,
an external source of compressed air is availa‐
2. Select IDLE.
ble.
3. Start the machine and watch the oil separa‐
1. Close the shut-off valve 10 in the venting
tor tank pressure gauge 2 until it reads 43–
line.
73 psig.
2. With the shut-off valve closed, insert the
4. Switch off and lock out the power supply
male hose fitting 6 into the hose cou‐
disconnecting device and verify the absence
pling 3 .
of any voltage.
3. Connect the maintenance hose to the exter‐
5. Wait at least 2 minutes to allow the oil to
nal air supply.
flow back to the separator tank.
4. Open the shut-off valve 7 until the pressure
gauge on the oil separator tank reads 43–
73 psig.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.
Draining the oil from the separator tank
1. Have an oil receptacle ready.

90 CSD 100/125 T 901726 08 USE
10 Maintenance
3. Place the other end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valve 11 .
5. Slowly open the shut off valve 7 in the maintenance hose to release oil and close immediately
when air escapes.
6. Close the shut-off valve 11 and unplug the male hose fitting.
Draining the oil from the cooler
Fig. 40 Changing the cooling oil, oil cooler

1 Oil cooler 6 Plug-in nozzle
2 Hose coupling (oil drainage) 7 Shut-off valve
3 Shut-off valve

4. Open the shut-off valve 3 .
5. Slowly open the shut-off valve 7 and allow cooling oil and air to escape completely until the
pressure gauge reads 0 psig.

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10 Maintenance
Draining the oil from the airend
Fig. 41 Changing the cooling oil, airend

1 Airend discharge port 4 Safety screen
2 Hose coupling (oil drainage) 5 Coupling
3 Shut-off valve

2. With the shut-off valve closed, insert the male hose fitting 6 (Fig. 39) into the hose coupling 2 .
4. Open shut-off valves 3 and 7 (Fig. 39)
5. Remove the coupling safety screen 4 and turn the coupling 5 by hand at least five revolutions
until all the oil has run out.
6. Fit the safety screen again.
Result The cooling oil is drained from the airend.

Turning the coupling lets a small quantity of cooling oil return to the oil separator container.
Thus, please repeat the step "Draining cooling oil from the oil separator container", in order to also
drain this cooling oil.

92 CSD 100/125 T 901726 08 USE
10 Maintenance
Option W2/W3 Draining the oil from the heat exchanger
Fig. 42 Changing the cooling oil, heat recovery system

1 Hose coupling
2 Thermostatic valve
3 Shut-off valve

2. Insert the male hose fitting 6 (Fig. 39) in the hose coupling 1 .
4. Open the shut-off valves 3 and 7 (Fig. 39) and allow the oil to drain completely.
Filling with cooling oil
1. Compressed air!
2. Slowly open the filler plug 4 (Fig. 39).
3. Fill with cooling oil.
4. Check the filler plug and ring seal for damage and screw the plug back in again.
Starting the machine and performing a trial run
3. Switch on the power supply and reset the maintenance interval counter.
4. Start the machine and check the oil level again after about 10 minutes, topping off if necessary.
➤ Dispose of used oil in accordance with environmental protection regulations.

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10 Maintenance
10.18 Changing the oil filter element
10.18 Changing the oil filter element

Material Spare parts

Cleaning cloth

the absence of any voltage has been verified,
the machine is fully vented,
the pressure gauge on the oil separator tank reads 0 psig.
There is risk of burns from hot components and oil!

Fig. 43 Changing the oil filter element

1 Oil filter cartridge
2 Direction of rotation for opening the filter housing
Changing the oil filter element
1. Compressed air!
2. Unscrew the cover of the filter housing.
3. Remove the old oil filter element and dispose of according to environmental protection regula‐
tions.
4. Insert the new oil filter element.
5. Ensure the correct torque when screwing the cover of the filter housing down.
The required torque is indicated on the cover.

94 CSD 100/125 T 901726 08 USE
10 Maintenance
10.19 Changing the oil separator cartridge
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
Starting the machine and performing a trial run
4. Start the machine and check the oil level again after about 10 minutes, topping off if necessary.

The oil separator element cannot be cleaned.
The life of the oil separator cartridge is influenced by:

■ contamination in the air drawn into the compressor,
■ and adherence to the changing intervals for:
─ Cooling oil
─ Oil filter
─ Air filter
Material Spares
Cleaning cloth

The machine is fully vented,
the pressure gauge on the oil separator tank reads 0 psig.

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10 Maintenance
Fig. 44 Changing the oil separator cartridge

14 Cover 19 Self-locking nut
15 Dirt trap 20 Screw connection
16 Air pipe 21 Gasket
17 Fixing screw 23 Oil separator cartridge
Changing the oil separator cartridge
1. Compressed air!
2. Unscrew the fitting 20 and carefully put the parts to one side, then pull out the copper pipe at
item 15 .
3. Unscrew the nut 19 and turn the air pipe 16 to one side.
4. Remove the cover fixing screws 17 and carefully remove the cover 14 .
5. Take out the old oil separator cartridge 23 together with the gaskets 21 and dispose of ac‐
cording to environmental protection regulations.
6. Clean all sealing faces.
7. Insert the new oil separator cartridge with gaskets and screw down the cover.
8. Renew the O-ring and strainer in the dirt trap 15 .
9. Attach the air pipe to the cover 14 with a new, self-locking nut.
10. Replace and tighten all fittings.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
Starting the machine and carrying out a trial run
4. After approx. 10 minutes of operation: Switch off the machine and check visually for leaks.

96 CSD 100/125 T 901726 08 USE
10 Maintenance
10.20 Cleaning the refrigerant condenser
10.20 Cleaning the refrigerant condenser

Repairs may only be carried out by certified personnel.
Material Brush and vacuum cleaner

Face mask (as required)
Fig. 45 Refrigeration dryer

1 Refrigerant condenser
2 Brush
Do not use sharp objects to clean the refrigerant condenser. The refrigerant condenser could be
damaged.
Avoid creating clouds of dust.

➤ Dry brush the refrigerant condenser and use a vacuum cleaner to remove any dirt.
The refrigerant condenser can no longer be cleaned?
➤ Have stubborn clogging removed by an authorized KAESER service representative.
10.21 Maintaining the condensate drain

Condensate is drained at two locations via electronic condensate drains:
■ At the cyclone separator
■ At the condensate separator of the refrigeration dryer
10.21.1 Condensate drain check

Precondition The power supply disconnecting device is switched on.
Machine is pressurized.
The Power LED lights.

901726 08 USE CSD 100/125 T 97
10 Maintenance
Fig. 46 Condensate drain check

1 Power LED
2 «TEST» button
3 Alarm LED
1. Danger of burns from hot components near the condensate drain!

➤ Work with caution.
2. With one hand, lightly touch the condensate drain hose at the condensate drain.
3. With your other hand, push and hold the «TEST» button at the condensate drain for at least
2 seconds.
Result As soon as the condensate drain opens, you will feel a short burst at the condensate drain hose.
Replace the service unit if you do not experience a burst during manual test.
10.21.2 Changing the service unit

➤ Take note of different connection variants and have the service units changed by a professio‐
nal.
10.21.2.1 Changing the service unit on the cyclone separator
The condensate drain cannot be cleaned. The service unit must be changed if condensate does
not drain.
Material Sealing tape for sealing the screw-in part

If required: O-ring 16x2 (5.1519.0)

98 CSD 100/125 T 901726 08 USE
10 Maintenance
Fig. 47 Changing the service unit

1 Service unit 8 Condensate inlet
2 Control module 9 Shut-off valve
3 Sensor 10 O-ring
4 Sensor opening 11 Screw-in part
5 Snap fastener 12 Sealing tape
6 Condensate drain hose fitting 13 Union nut with vent holes
7 Contact springs 14 Insulation (if provided)
Removing the service unit
1. Serious injury or death can result from loosening or opening components under
pressure!
➤ Fully vent all pressurized components and enclosures.
2. Close the shut-off valve 9 upstream of the condensate drain.
3. Unscrew the fitting 6 at the condensate line.
4. Press the snap fastener 5 and carefully remove the control module 2 from the service unit 1 .
5. Carefully loosen the union nut 13 at the shut-off valve 9 until remaining residual air has esca‐
ped through the venting holes.
6. Unscrew the screw-in part 11 from the service unit and place aside.
7. Remove the insulation 14 from the service unit.
Installing the service unit
Use only KAESER service units to ensure correct function of the condensate drain.
Precondition Make sure that the top of the service unit and the contact springs are clean and dry.
1. Fit the insulation 14 to the service unit 1 .

901726 08 USE CSD 100/125 T 99
10 Maintenance
2. Carefully insert the sensor 3 of the control module 2 in the opening 4 at the service unit.
3. Place the snap fastener 5 of the control module into the service unit eyes.
4. Press the control module to the service unit until the snap fastener can be heard to click into
place.
5. At the screw-in part 11 , replace old sealing material with new sealing tape.
6. Install the screw-in part in the service unit.
7. If necessary, insert a new o-ring 10 .
8. Tighten the union nut 13 at the shut-off valve 9 .
9. Attach the condensate hose.
10. Open the shut-off valve upstream of the condensate drain.
10.21.2.2 Changing the service unit on the condensate separator
The condensate drain cannot be cleaned. The service unit must be changed if condensate does
not drain.

The Power LED is off (see Fig. 46).
Fig. 48 Changing the service unit

1 Service unit 6 Condensate drain hose fitting
2 Control module 7 Contact springs
3 Sensor 8 Condensate inlet
4 Sensor opening 9 Shut-off valve
5 Snap fastener
Removing the service unit
1. Close the shut-off valve 9 upstream of the condensate drain.

2. Unscrew the drain hose fitting.
3. Press the snap fastener 5 and remove the control module carefully from the service unit.
4. Carefully unscrew the service unit from the pipe at the condensate inlet.

100 CSD 100/125 T 901726 08 USE
10 Maintenance
Installing the service unit
Use only KAESER service units to ensure correct function of the condensate drain.
Precondition Make sure that the top of the service unit and the contact springs are clean and dry.
1. Screw the service unit to the inlet pipe.

2. Carefully insert the control module sensor 3 in the opening 4 in the new service unit.
3. Place the hook of the control module into the service module eye and press until the snap fas‐
tener can be heard to click into place.
4. Attach the condensate hose and open the shut-off valve 9 upstream of the condensate drain.

901726 08 USE CSD 100/125 T 101
10 Maintenance
10.22 Documenting maintenance and service work
10.22 Documenting maintenance and service work

Equipment number:
➤ Enter maintenance and service work carried out in the checklist below.
Date Maintenance task carried out Operating hours Signature
Tab. 64 Logged maintenance tasks

102 CSD 100/125 T 901726 08 USE
11.1 Note the nameplate

11.1 Note the nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every inquiry and order for spare parts.
11.2 Ordering spare parts and operating fluids/materials

KAESER spare parts and operating materials are original KAESER products. They are specifically
selected for use in KAESER machines.
Unsuitable or poor quality spare parts and operating fluids/materials may damage the machine or
impair its proper function.
Damage to the machine can also result in personal injury.
There is risk of personal injury or damage to the machine resulting from the use of unsuita‐
ble spare parts or operating fluids/materials.
➤ Use only original parts and operating fluids/materials.
➤ Have an authorized KAESER service representative carry out regular maintenance.
Machine
Name Number
Air filter: Pre-filter 1249
Air filter: Air filter element 1250
Filter mat (control cabinet) 1100
Filter mat (Option K3) 1050
Oil filter 1200
Oil separator cartridge 1450
Cooling oil 1600
Condensate drain: 9602
Service unit
Bearing grease 100 g 9.0915.0
400 g 6.3234.0
Tab. 65 Spare parts
11.3 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ authorized KAESER service representatives with KAESER factory training,
■ increased operational reliability ensured by preventive maintenance,
■ energy savings achieved by avoidance of pressure losses,

901726 08 USE CSD 100/125 T 103
11.4 Replacement parts for service and repair
■ optimum conditions for operation of the compressed air system,

■ the security of genuine KAESER spare parts,
■ increased legal certainty as all regulations are kept to.
➤ Why not sign a KAESER AIR SERVICE maintenance agreement!
Result Your advantage:

lower costs and higher compressed air availability.

Use these parts lists to plan your material requirement according to operating conditions and to or‐
der the required spare parts.
➤ Make sure that any service or repair tasks not described in this manual are carried out by

104 CSD 100/125 T 901726 08 USE

901726 08 USE CSD 100/125 T 105

106 CSD 100/125 T 901726 08 USE

901726 08 USE CSD 100/125 T 107

108 CSD 100/125 T 901726 08 USE

901726 08 USE CSD 100/125 T 109

110 CSD 100/125 T 901726 08 USE
12.1 Decommissioning

12.1 Decommissioning
Decommissioning is necessary, for example, under the following circumstances:
■ The machine is (temporarily) not needed.
■ The machine is to be moved to another location.
■ The machine is to be scrapped.
➤ The following tasks must be carried out only by authorized personnel.
12.1.1 Temporary decommissioning

Precondition The machine can be started at regular intervals.
➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protec‐
tion against corrosion.
12.1.2 Long-term decommissioning

Precondition Immediately prior to decommissioning, run the machine under LOAD for at least 30 minutes.
12.1.2.1 Draining condensate
If the machine is equipped with one or more condensate drain(s), drain condensate from every
condensate drain.
1. Drain condensate from all condensate drains and dispose according to applicable environment
2. Remove the user-supplied condensate conduits.
The condensate drains are not supplied with power when the machine is switched off?
➤ Detach and drain the condensate drains.
12.1.2.2 Isolating the machine from supply lines

The machine is fully vented.
The user's shut-off valve to the compressed air network is closed or the compressed air network
has been fully vented.
1. Allow the machine to completely cool down.

2. Detach the power supply and connecting line to the compressed air network at the user side.
3. Option K2/K9:
Detach the user connecting lines and use compressed air (<30 psig) to blow out the cooling
water system until liquid no longer escapes.

901726 08 USE CSD 100/125 T 111
12.2 Packing
4. Option W2/W3:
Detach the user connecting lines and use compressed air (<30 psig) to blow out the heat re‐
covery system until liquid no longer escapes.
5. Properly close all open connecting ports.
12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Other measures must be taken for the transport of machines by sea or air. Please contact an au‐
thorized KAESER SERVICE representative for more information.
Material Desiccant
Plastic sheeting
Wooden crate
Precondition The machine is decommissioned.

The machine is dry and cooled down.
1. Place sufficient desiccant silica gel or desiccant clay in the machine.

2. Wrap the machine fully in plastic sheeting.
3. Protect the machine in a wooden crate against mechanical damages.
12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator
tank.
Frozen moisture can damage components, valve diaphragms and gaskets.
The following measures also apply to machines not yet commissioned.
Please consult with KAESER if you have questions to the appropriate storage and commis‐
sioning.
1. Moisture and frost can damage the machine!

➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >32 °F.
2. Store the machine in a dry, frost-proof room.
12.4 Transport
12.4.1 Safety
Weight and center of gravity determine the most suitable method of transportation. The center of
gravity is shown in the drawing in chapter 13.3.
➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐
tures.

112 CSD 100/125 T 901726 08 USE
12.4 Transport
Precondition Transport only by forklift truck or lifting gear and only by personnel trained in the safe transportation
of loads.
➤ Make sure the danger area is clear of personnel.
12.4.2 Transport with a forklift truck

Precondition The forks are fully under the machine.
Fig. 49 Transport with a forklift truck
1. Take note of the center of gravity.

2. Drive the forks completely under the machine or palette and lift carefully.
12.4.3 Transport with a crane

Only suitable and approved load-carrying and attachment devices ensure proper transport of the
machine with a crane. Suitable crossbeams ensure sufficient distance of the attachment resources
from the machine housing to prevent damage.
The machine is not equipped with fixing points.
Examples of unsuitable fixing points:

■ Pipe sockets
■ Flanges
■ Attached components such as centrifugal separators, condensate drains or filters
■ Rain protection covers
➤ Consult KAESER if you require suitable load-carrying and attachment devices or have
questions regarding the correct use.
Precondition Load-carrying and attachment devices meet the local safety regulations.
The hoist, load-carrying and attachment devices or the lifted machine do not endanger personnel.

901726 08 USE CSD 100/125 T 113
12.4 Transport
Fig. 50 Transport with a crane

1 Load carrying devices
2 Attachment resources
3 Crossbeam
1. Risk of accident caused by incorrect use of load-carrying and attachment devi‐

ces!
➤ Comply with permissible load limits.
➤ Comply with specific safety information of used load-carrying and attachment devices.
2. Properly use load-carrying and attachment devices:
■ Ensure proper distribution of the fastening points relative to the center of gravity position
(symmetrical load distribution).
■ Ensure equal slope angles of 15° to 45° for attachment devices with multiple strands.
─ Slope angles between 45° and 60° may be unsuitable.
─ Slope angles larger than 60° are prohibited.
■ Ensure the maximum incline of 6° of the machine to the horizontal.
■ Ensure sufficient distance of the attachment devices to the machine.
■ Ensure a positive stability height: Dimension B > Dimension A.
■ Do not attach the attachment devices to any machine component.
3. Carry out a lifting test:
Slightly lift the machine to check whether machine remains in horizontal position and does not
teeter.
4. Transport the machine only after a successful lifting test.

114 CSD 100/125 T 901726 08 USE
12.5 Disposal
12.5 Disposal
When disposing of a machine, drain out all liquids and remove old filters.
Precondition The machine is decommissioned.
1. Completely drain the cooling oil from the machine.

2. Remove used filters and the oil separator cartridge.
3. Hand the machine over to an authorized disposal expert.
➤ Parts contaminated with cooling oil must be disposed of in accordance with local environ‐
ment protection regulations.
Compressors with refrigeration dryers
The refrigerant circuit still contains both refrigerant and oil.

➤ Refrigerant and oil must be drained and disposed of by authorized personnel.
12.5.1 Battery disposal

Batteries contain substances that are harmful to living beings and the environment. For this reason,
batteries must not be disposed of with unsorted residential waste. They must be disposed of in ac‐
cordance with local environmental regulations. This procedure facilitates the handling and recycling
of batteries.
Fig. 51 Battery disposal

1 Do not dispose of batteries with residential waste
2 Battery contains lead (if applicable)
➤ Dispose of batteries in accordance with local environmental regulations.

901726 08 USE CSD 100/125 T 115
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)
13 Annex

116 CSD 100/125 T 901726 08 USE
13 Annex

901726 08 USE CSD 100/125 T 117
13 Annex

118 CSD 100/125 T 901726 08 USE
13 Annex

901726 08 USE CSD 100/125 T 119
13 Annex

120 CSD 100/125 T 901726 08 USE
13 Annex

901726 08 USE CSD 100/125 T 121
13 Annex
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode
13.2 Option C1
Pipe and Instrument Flow Diagram (P+I diagram): MODULATING
control mode

122 CSD 100/125 T 901726 08 USE
13 Annex

901726 08 USE CSD 100/125 T 123
13 Annex

124 CSD 100/125 T 901726 08 USE
13 Annex

901726 08 USE CSD 100/125 T 125
13 Annex

126 CSD 100/125 T 901726 08 USE
13 Annex

901726 08 USE CSD 100/125 T 127
13 Annex
13.3 Dimensional drawing
13.3 Dimensional drawing

128 CSD 100/125 T 901726 08 USE
42 1/4 38 7/8
38 1/8
W2 W3
90° ID NPT 1 1/4
901726 08 USE
22 7/8
9 1/2
3 7/8
View A
2 3/4
7 3/4 5 3/8
3 3/8
90°
5 1/8
1 5/8
42 1/2
Z Z
16 3/8
2 3/8
2 x dia. 2 1/4
7 1/4
30 1/4
4 x dia. 1
13
22 1/2
13.3
20 1/4
1 5/8
90° 90°
Subject to development-related changes.

Drawing may be altered only via CAD.
1 5/8
Electrical connections (optional)
CSD 100/125 T
1 5/8
Operator Manual
31 7/8
Outlet: compressed air

Annex
53 1/8
53 1/8 K3
38 5/8 42 1/2 50 3/4
Outlet: cooling air
Dimensional drawing
Inlet:
cooling air


38 5/8
76 3/4
ID NPT 2 K3
Inlet: Inlet:
ID NPT 1/4 intake air cooling air
47 1/8
32 5/8
32 1/4
Y
3 7/8
2 3/8
dia. 4 7/8 5 3/4 3 3/4 25 5/8 45 1/8 5 1/2 2 7/8 39 5/8
8 5/8
A 5 1/2 2 7/8 45 1/4
Connection: 92 1/2
condensate drain
98 3/4
H1 H1
Y
dia. 3/4 Lubricating fitting: Lubricating fitting: 2 7/8 39 5/8
compressor motor fan motor
dia. 7 1/8
3 7/8
ID : Internal thread Dimensions shown in inches
50 5/8 28 3/8 Change number Projection Scale Date Name
1:20 Drawn 27.08.2013 ROEBLITZ1
Document TZM Original Edited 05.11.2013 ROEBLITZ1 Language Sheet
W3 int. heat recovery ΔT=55K 10255247 USE 00 A2 Released 12.11.2013 SCHUBT4 USE 1/1
: Center of gravity
Position marginally dependent on design W2 int. heat recovery ΔT=25K Document TZD Designation
H1 Adjustable machine feet 10255247 D 00
CSDX.4 T K1
K1 Air cooling Status Dimension and connection dim.
Transport opening ≥ machine width + 3,9 inch Released
Drawings remain our exclusive property.

They are entrusted only for the agreed upon purpose.
Copies or any other reproduction, including storage, treatment and distribution by use of electronic systems is not allowed for any other than the agreed upon purpose.
Neither originals nor reproductions may be given to or made available to third parties.
Stand 17.10.2013
K3 Cooling air filter mats
129
130
75 7/8 3 3/8
49 1/4
38 1/8
W2 W3
31 7/8
ID NPT 1 1/4
90° 9 1/2
3 7/8
View A 90°
2 3/4
7 3/4 5 3/8
5 1/8
1 5/8
3 3/8
90°
Z ID NPT 1 1/4 42 1/2
Z
2 3/8
K2 K9
13
2 x dia. 2 1/4
13.3
7 1/4
44 5/8
4 x dia. 1 12 3/8
30 1/4

25 1/2

1 5/8
CSD 100/125 T
Operator Manual
1 5/8
90° 90°
Annex
1 5/8
31 7/8
Dimensional drawing
50 3/4
Outlet: cooling air

ID NPT 2 53 1/8 22 1/2
78 1/8
76 3/4
Inlet:
Inlet: cooling air
ID NPT 1/4 intake air
47 1/8
32 5/8
3 7/8
2 3/8
dia. 4 7/8 5 3/4 3 3/4 25 5/8 45 1/8 5 1/2 2 7/8 39 5/8
8 5/8
A
5 1/2 2 7/8 45 1/4
92 1/2
Connection:
H1 condensate drain Y 98 7/8 H1
Lubricating fitting: Lubricating fitting:

dia. 3/4 compressor motor fan motor 2 7/8 39 5/8
dia. 7 1/8
3 7/8
ID : Internal thread Dimensions shown in inches
Change number Projection Scale Date Name
50 5/8 28 3/8
W3 int. heat recovery ΔT=55K 10255376 USE 00 A2 Released 11.11.2013 SCHUBT4 USE 1/1
: Center of gravity
Position marginally dependent on design W2 int. heat recovery ΔT=25K Document TZD Designation
K2 Water cooling plate heat exch. 10255376 D 00
CSDX.4 T K2 K9
K9 Water cool. bundled-pipe exch. Status Dimension and connection dim.
Transport opening ≥ machine width + 3,9 inch Released

Stand 17.10.2013
H1 Adjustable machine feet
901726 08 USE
K1 K2 K9
901726 08 USE
41 3/4
11 7/8 16 3/4 11 7/8
dia
.5 1 3/4 15 3/8
1 1/8
/8
9 1/4
12 3/8
20 1/4
1 1/8
25 1/2
9 1/8
15 3/8
1 3/4
19 7/8
16 3/8
13
13.3

33 1/2
38 7/8 26 1/2 max. drilling depth 5/8Inch
CSD 100/125 T
49 1/4
Operator Manual
max. drilling depth 5/8Inch
42 1/4
Annex
.
CSD 100 : V = 6.500 cfm Outlet: cooling air
.
CSD 125 : V = 7.700 cfm
max. drilling depth 5/8Inch 42 1/2 .

CSD 100/125 : V = 850 cfm Outlet: cooling air
38 5/8 26 3/4
Dimensional drawing
1 3/8

Inlet:
cooling air
41 3/8
38 5/8
.
CSD 100 : V = 5.700 cfm
.
CSD 125 : V = 6.900 cfm
1 3/8
40 3/4 32 1/4
Change number Projection Scale Date Name

10255478 USE 00 A2 Released 14.11.2013 SCHUBT4 USE 1/1
Total permissible pressure loss for installed ducting
Document TZD Designation
with filtermats without filter
K2 Water cooling plate heat exch. 10255478 D 00
CSDX.4 K1 ∆ p max . 1/4 inch water column 1/8 inch water column CSDX.4 K1 K2 K9
K9 Water cool. bundled-pipe exch. Status Connection, dp cool. air duct
CSDX.4 K2/K9 ∆ p max . 1/8 inch water column - Released

Stand 17.10.2013
K1 Air cooling
131
13 Annex
13.4 Electrical Diagram

132 CSD 100/125 T 901726 08 USE
1 2 3 4 5 6 7 8
901726 08 USE
Wiring Diagram
compressor CSD 100/125 T
13
air cooled or water cooled

13.4
230V±10% 3ph 60Hz 380V±10% 3ph 60Hz
CSD 100/125 T
Operator Manual
460V±10% 3ph 60Hz
Annex
Power supply:
WYE system with center point solidly grounded
Electrical Diagram
ATTENTION !!!
The document gives collective information on manufacturer: KAESER COMPRESSORS
power supply voltages and frequencies for all machines.

The voltage and frequency and local conditions under 96450 COBURG
which any particular machine may be used
are given on the nameplate of the machine GERMANY
and in the accompanying service manual.
The drawings remain our exclusive property. They are entrusted

only for the agreed purpose. Copies or any other reproductions,
including storage, treatment and dissemination by use of
electronic systems must not be made for any other than the
agreed purpose. Neither originals nor reproductions must be
forwarded or otherwise made accessible to third parties.
c Datum 04.09.2017 USE cover page =

b Bearbeiter Sitter +
a ÄNr.: 43127 23.11.17 Ge/Si Geprüft Gegner
compressor CSD 100/125 T page 1
A Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS DCSDX.T-U3056.00 1 Bl.
133
134
Lfd. Nr. Benennung Zeichnungsnummer (Kunde) Zeichnungsnummer (Hersteller) Blatt Anlagenkennzeichen
No. Name Drawing No. (customer) Drawing No. (manufacturer) Page Unit designation
1 cover page DCSDX.T-U3056.00 1
2 list of contents ZCSDX.T-U3056.00 1
3 general instructions UCSDX.T-U3056.00 1
4 electrical equipment identification UCSDX.T-U3056.00 2
5 electrical component parts list UCSDX.T-U3056.00 3
8 wiring diagram power supply/power unit SCSDX.T-U3056.00 1
13
13.4
9 wiring diagram compressor motor SCSDX.T-U3056.00 2

10 wiring diagram vent motor / option K1 SCSDX.T-U3056.00 3
11 wiring diagram binary inputs/outputs SCSDX.T-U3056.00 4
12 wiring diagram air dryer SCSDX.T-U3056.00 5
CSD 100/125 T
13 wiring diagram air dryer control SCSDX.T-U3056.00 6
Operator Manual
14 wiring diagram control voltage tapping SCSDX.T-U3056.00 7
Annex
15 wiring diagram power supply unit SCSDX.T-U3056.00 8

16 wiring diagram IO-module/configuration SCSDX.T-U3056.00 9
17 wiring diagram sensors/actuators SCSDX.T-U3056.00 10
18 wiring diagram volt-free contacts SCSDX.T-U3056.00 11
19 wiring diagram inputs-/outputs SCSDX.T-U3056.00 12
Electrical Diagram
20 wiring diagram transformer diagrams SCSDX.T-U3056.00 13

21 wiring diagram Handling: Terminals SCSDX.T-U3056.00 14
22 wiring diagram Feed line connection SCSDX.T-U3056.00 15
23 terminal connection terminal strip -X11,-X12,-X10 KCSDX.T-U3056.00 1
24 terminal connection terminal strip -X32 KCSDX.T-U3056.00 2

25 lay-out control panel 380V/460V ACSDX.T-U3056.00 1
26 lay-out control panel 230V ACSDX.T-U3056.00 2
c Datum 04.09.2017 list of contents =

a Geprüft Gegner
B Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS ZCSDX.T-U3056.00 1 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
901726 08 USE
general instructions control cabinet wiring for non-designated conductors
ATTENTION !!!
primary circuits ungrounded: black, UL-Style 1015, CSA-TEW
Install supplies, grounding and shock protection
primary circuits grounded: grey, UL-Style 1015, CSA-TEW
to local safety regulations.
control voltage AC 115V ungrounded: red, 18AWG UL-Style 1015, CSA-TEW
Do not make or break
live plug-in connectors. control voltage AC 115V grounded: white, 18AWG UL-Style 1015, CSA-TEW
13
13.4
control voltage DC ungrounded: blue, 18AWG UL-Style 1015, CSA-TEW

control voltage DC grounded: white/blue, 18AWG UL-Style 1015, CSA-TEW
external voltage: orange, 16AWG UL-Style 1015, CSA-TEW
CSD 100/125 T
Operator Manual
measuring circuits: violet, 18AWG UL-Style 1015, CSA-TEW
Annex
ground conductor: green/yellow, UL-Style 1015, CSA-TEW

Electrical Diagram

option K1 = air cooling
option K2/K9 = water cooling
option T2 = transformer power supply for refrigeration dryer
option C47 = Surge protective device
c Datum 04.09.2017 general instructions =

a Geprüft Gegner
C Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS UCSDX.T-U3056.00 5 Bl.
135
136
1 2 3 4 5 6 7 8
electrical equipment identification

general components control sensors/actuators
-B25 overload relay, -K20 Main Control System SC2MCS -B1 pressure transducer,
compressor motor -X1 Ethernet air main pressure
-1FU,-2FU primary control fuse -X2 IO-Bus -B2 safety air pressure switch-direction of rotation
-3FU secondary control fuse -X3 RS485-FC (USS) -B3 high oil filter pressure
-4FU secondary control fuse - -X4 communication module (Bus) -B4 pressure transducer,
option K1 230V -X5 SD card slot package internal pressure
13
13.4
-11FU secondary control fuse, air dryer - -X6 ground connection -B5 high air filter pressure
option T2 -B30 safety air pressure switch (Pressure limiter),
-33FU,-40FU fuse -K21 IO-module SC2IOM-1 air dryer
-F31,-F32 circuit breaker, air dryer -B31 pressure switch (Liquefaction pressure),
inside
CSD 100/125 T
-F86 Surge protective device - air dryer
Operator Manual
-X1 IO-Bus, input
option K1/C47, Canada only -B33 pressure switch (Gassing pressure),
Annex
-X2 IO-Bus, output

-K54 control relay STO - option K1 air dryer
-X3,-X8 digital inputs
-M1 compressor motor -X4 power supply unit, digital outputs -B39 temperature probe (pressure dew point),
-M4 vent motor - option K1 air dryer
-X5,-X9 Relay outputs
-M5 vent motor - option K2/K9 -B40 temperature probe,
-X6 analog input, 4-20mA
-M7 controller ventilator airend discharge temperature
Electrical Diagram
-X7 analog input, Pt100

-M30 Refrigerant compressor air dryer -B43 temperature probe,
-M31,-M32 vent motor air dryer external inlet temperature
-Q1 main contactor -X11...-X13 analog inputs, 4-20mA -B60 temperature probe,
-Q2 delta contactor -X14...-X17 analog inputs, Pt100 compressor motor
-Q3 wye contactor -X18...-X29 digital inputs -K1 control valve

-Q4 contactor vent motor - option K2/K9 -X30...-X32 digital outputs -K10 condensate drain, centrifugal separator
-Q30 motor starter -K34 condensate drain, air dryer
Refrigerant compressor, air dryer -M20 control valve oil temperature
-Q31 motor starter
vent motor, air dryer
-R4 line commutation reactor
frequency converter - option K1 terminal strips
-R14 interference suppression filter
-X0 terminal strip, power supply
frequency converter - option K1
-X10 terminal strip, option K1 230V / C47
-S1 EMERGENCY STOP pushbutton
-X11 terminal strip, control
-T4 frequency converter - option K1
-X12 terminal strip, control 24VDC
-T11 control transformer -X32 terminal strip, air dryer
-T14 auto-transformer -
option K1/230V
-T21 power unit
-T30 auto-transformer - option T2 230V/380V
c Datum 04.09.2017 electrical equipment identification =

a Geprüft Gegner
C Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung:
SC2 MCS UCSDX.T-U3056.00 5 Bl.
901726 08 USE
13 Annex
3
performance-related components
Bl.
5
page
model CSD 100 T
machine power supply 230 V ±10 %, 60 Hz 380 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz
UCSDX.T-U3056.00
motor -M1 100 hp 100 hp 100 hp
=
+
supply terminals -X0:U1/V1/W1 6x 895545.0 6x 894385.0 6x 894385.0
285-1185 285-195 285-195
Handling fig. 2, Sht. 14 fig. 2, Sht. 14 fig. 2, Sht. 14
Stripped length 45 mm 35 mm 35 mm
WAGO 1/0 AWG - 350 MCM 4 - 4/0 AWG 4 - 4/0 AWG
GRD rail PE-terminal 7.3605.0 7.3605.0 7.3605.0
01068 01068 01068
Torque 133 lb-in 133 lb-in 133 lb-in
Wöhner 4 AWG - 250 MCM 4 AWG - 250 MCM 4 AWG - 250 MCM
SC2 MCS
PE-terminal 7.6455.0 --- ---
SV3454.500
Stripped length 35 mm
Torque 133 lb-in
Rittal 2/0 AWG - 350 MCM
supply connection fig. 10+ 11, Sht. 15 fig. 10+ 11, Sht. 15 fig. 10+ 11, Sht. 15
contactor -Q1/-Q2 7.3140.02170 7.3140.02140 7.8740.00450
3RT1064-6AF36 3RT1054-1AF36 3RT2046-1AK60

auxiliary switch --- --- 7.8740.05010
3RH2911-1HA11
interference suppressor 7.3140.02020 7.3140.02020 7.8740.05170
electrical component parts list

Siemens 3RT1956-1CC00 3RT1956-1CC00 3RT2946-1CC00
contactor -Q3 7.3140.02140 7.8740.00440 7.8740.00420
3RT1054-1AF36 3RT2045-1AK60 3RT2037-1AK60
overload relay -B25 7.6873.00250 7.6873.00230 7.8741.00140
3RB2066-1GC2 3RB2056-1FC2 3RB3046-1XB0
55-250 A 50-200 A 32-115 A
setting: 136 A setting: 81 A setting: 66 A
NEC 430.32(C) incremental NEC 430.32(C) incremental NEC 430.32(C) incremental
Siemens setting: 152 A setting: 91 A setting: 74 A
line commutation reactor -R4 7.7831.00600 7.7831.00530 7.7831.00600
(option K1) B 1511129 B 1506104 B 1511129
Block 460 V 380 V 460 V
Ursprung:
fuse socket -1FU/-2FU/-3FU 7.3320.00060 7.3320.00060 7.3320.00060
Class CC 3-pol Class CC 3-pol Class CC 3-pol
Wöhner 31297 31297 31297
fuse -1FU/-2FU/-3FU 7.3161.00141 7.3313.1 7.3313.1
(option K1) ATQR 4 ATQR 2-1/2 ATQR 2-1/2
Gould 4 A, 600 V 2.5 A, 600 V 2.5 A, 600 V
transformer -T11 7.7569.00010 7.2239.20080 7.7569.0
(option K1) 208/230/460 V-115 V USTE250/2X115 208/230/460 V-115 V
Ersatz für:
400 VA 250 VA 250 VA
Block diagram 1, Sht. 13 diagram 2, Sht. 13 diagram 1, Sht. 13
fuse -1FU/-2FU/-3FU 7.3161.00170 7.3161.00141 7.3161.00141
(option K2/K9) ATQR 6 ATQR 4 ATQR 4
Gould 6 A, 600 V 4 A, 600 V 4 A, 600 V
transformer -T11 7.2238.10040 7.2239.20070 7.7569.00010
(option K2/K9) STE 630 USTE400/2X115 208/230/460 V-115 V
2x 220-230-240/2x115 V 400 VA 400 VA
Ersatz durch:

circuit breaker -F31/-F32 7.8742.00060 7.8742.00060 7.8742.00060
3RV2011-0FA10 3RV2011-0FA10 3RV2011-0FA10
0.35-0.5 A 0.35-0.5 A 0.35-0.5 A
Siemens setting: 0.42 A setting: 0.42 A setting: 0.42 A
04.09.2017
connection -W11 4/0 AWG black 2/0 AWG black 1 AWG black a
Gegner
Sitter
600 V, 90°C 600 V, 90°C 600 V, 90°C

connection -W13 4/0 AWG black 2/0 AWG black 1 AWG black a
Bearbeiter
600 V, 90°C 600 V, 90°C 600 V, 90°C

Geprüft
Datum
Norm
connection -W14 1 AWG black 2 AWG black 6 AWG black

600 V, 90°C 600 V, 90°C 600 V, 90°C
Name
23.11.17 Ge/Si
connection -W15 7.3140.01800 7.3140.00940 7.3140.01170

3RT1956-4BA31 3RT1946-4BA31 3RT1936-4BA31
Datum
600 V, 90°C 600 V, 90°C 600 V, 90°C

motor cable -W19 3/0 AWG black 1 AWG black 2 AWG black
600 V, 90°C 600 V, 90°C 600 V, 90°C
a ÄNr.: 43127
C Änderung
b
c

901726 08 USE CSD 100/125 T 137
13 Annex
4
performance-related components
Bl.
5
page
model CSD 125 T
UCSDX.T-U3056.00
motor -M1 125 hp 125 hp 125 hp
=
+
supply terminals -X0:U1/V1/W1 6x 895545.0 6x 894385.0 6x 894385.0
285-1185 285-195 285-195
WAGO 1/0 AWG - 350 MCM 4 - 4/0 AWG 4 - 4/0 AWG
GRD rail PE-terminal 7.3605.0 7.3605.0 7.3605.0
01068 01068 01068
Torque 133 lb-in 133 lb-in 133 lb-in
Wöhner 4 AWG - 250 MCM 4 AWG - 250 MCM 4 AWG - 250 MCM
SC2 MCS
PE-terminal 7.6455.0 --- ---
SV3454.500
Stripped length 35 mm
Torque 133 lb-in
Rittal 2/0 AWG - 350 MCM
supply connection fig. 10+ 11, Sht. 15 fig. 10+ 11, Sht. 15 fig. 10+ 11, Sht. 15
contactor -Q1/-Q2 7.3140.02170 7.3140.02140 7.3140.02140
3RT1064-6AF36 3RT1054-1AF36 3RT1054-1AF36

contactor -Q3 7.3140.02140 7.8740.00440 7.8740.00430

3RT1054-1AF36 3RT2045-1AK60 3RT2038-1AK60
overload relay -B25 7.6873.00250 7.6873.00230 7.6873.00230
3RB2066-1GC2 3RB2056-1FC2 3RB2056-1FC2
55-250 A 50-200 A 50-200 A
setting: 156 A setting: 95 A setting: 78 A
NEC 430.32(C) incremental NEC 430.32(C) incremental NEC 430.32(C) incremental
Siemens setting: 175 A setting: 107 A setting: 87 A
line commutation reactor -R4 7.7831.00600 7.7831.00530 7.7831.00600
(option K1) B 1511129 B 1506104 B 1511129
Block 460 V 380 V 460 V
fuse socket -1FU/-2FU/-3FU 7.3320.00060 7.3320.00060 7.3320.00060
Class CC 3-pol Class CC 3-pol Class CC 3-pol
Ursprung:
Wöhner 31297 31297 31297
fuse -1FU/-2FU/-3FU 7.3161.00141 7.3313.1 7.3313.1
(option K1) ATQR 4 ATQR 2-1/2 ATQR 2-1/2
Gould 4 A, 600 V 2.5 A, 600 V 2.5 A, 600 V
transformer -T11 7.7569.00010 7.2239.20080 7.7569.0
(option K1) 208/230/460 V-115 V USTE250/2X115 208/230/460 V-115 V
400 VA 250 VA 250 VA
Ersatz für:
fuse -1FU/-2FU/-3FU 7.3161.00170 7.3161.00141 7.3161.00141
(option K2/K9) ATQR 6 ATQR 4 ATQR 4
Gould 6 A, 600 V 4 A, 600 V 4 A, 600 V
transformer -T11 7.2238.10040 7.2239.20070 7.7569.00010
(option K2/K9) STE 630 USTE400/2X115 208/230/460 V-115 V
2x 220-230-240/2x115 V 400 VA 400 VA
circuit breaker -F31/-F32 7.8742.00060 7.8742.00060 7.8742.00060
Ersatz durch:
3RV2011-0FA10 3RV2011-0FA10 3RV2011-0FA10

0.35-0.5 A 0.35-0.5 A 0.35-0.5 A
Siemens setting: 0.42 A setting: 0.42 A setting: 0.42 A
connection -W11 4/0 AWG black 2/0 AWG black 1 AWG black
600 V, 90°C 600 V, 90°C 600 V, 90°C
04.09.2017
connection -W13 4/0 AWG black 2/0 AWG black 1 AWG black
Gegner
Sitter
600 V, 90°C 600 V, 90°C 600 V, 90°C

connection -W14 2/0 AWG black 2 AWG black 6 AWG black
Bearbeiter
600 V, 90°C 600 V, 90°C 600 V, 90°C

Geprüft
Datum
Norm
connection -W15 7.3140.01800 7.3140.00940 7.3140.01170

3RT1956-4BA31 3RT1946-4BA31 3RT1936-4BA31
Name

600 V, 90°C 600 V, 90°C 600 V, 90°C
motor cable -W19 4/0 AWG black 2/0 AWG black 2 AWG black
Datum
600 V, 90°C 600 V, 90°C 600 V, 90°C

C Änderung
b
a
c

138 CSD 100/125 T 901726 08 USE
13 Annex
5
Common parts
Bl.
5
page
model CSD 100/125 T
machine power supply 230 V±10 %, 60 Hz 380 V±10 %, 60 Hz 460 V±10 %, 60 Hz
UCSDX.T-U3056.00
460 V±10 %, 60 Hz Canada
=
+
fuse socket -33FU/-40FU 7.3320.00060 7.3320.00060 7.3320.00060
Wöhner Class CC 3-pol 31297 Class CC 3-pol 31297 Class CC 3-pol 31297
fuse -40FU 3x 7.3161.00320 3x 7.3161.00310 3x 7.3161.00310
Gould ATDR 20 (20 A, 600 V) ATDR 15 (15 A, 600 V) ATDR 15 (15 A, 600 V)
transformer -T14 7.5452.00161 --- ---
(option K1) B 0708062
Block 3x 200-440 V/400-460 V, 5.5 A
fuse socket -4FU 7.3320.00060 --- ---
(option K1) Class CC 3-pol
Wöhner 31297
SC2 MCS
fuse -4FU 3x 7.3306.00010 --- ---
(option K1) Gould ATDR 7 (7 A, 600 V)
contactor -Q4 7.8740.00340 7.8740.00340 7.8740.00340
(option K2/K9) 3RT2023-1AK60 3RT2023-1AK60 3RT2023-1AK60
interference suppression filter -R14 7.8832.10010 7.8832.10010 7.8832.10010
(option K1) FS33891-16-07 FS33891-16-07 FS33891-16-07

Schaffner 380-480 V, 16 A 380-480 V, 16 A 380-480 V, 16 A
frequency converter -T4 7.8833.00040 7.8833.00040 7.8833.00040
(option K1) 6SL3210-1PE14-3UL1 6SL3210-1PE14-3UL1 6SL3210-1PE14-3UL1

1.5 kW, 380-480 V 1.5 kW, 380-480 V 1.5 kW, 380-480 V
Control Unit 7.7830.00710 7.7830.00710 7.7830.00710
Siemens 6SL3244-0BB12-1BA1 6SL3244-0BB12-1BA1 6SL3244-0BB12-1BA1
control relay -K54 7.8740.04110 7.8740.04110 7.8740.04110
(option K1) 3RH2122-1AK60 3RH2122-1AK60 3RH2122-1AK60
power supply -T21 7.7605P0 7.7605P0 7.7605P0
Prodrive PSDC24/2.5 PSDC24/2.5 PSDC24/2.5
compressor control -K20 7.7601.0 7.7601.0 7.7601.0
Prodrive SIGMA CONTROL 2 MCS SIGMA CONTROL 2 MCS SIGMA CONTROL 2 MCS
IO-module -K21 7.7602.1 7.7602.1 7.7602.1
Prodrive SIGMA CONTROL 2 IOM-1 SIGMA CONTROL 2 IOM-1 SIGMA CONTROL 2 IOM-1
EMERGENCY STOP pushbutton -S1 7.3217.0 / QRUV 7.3217.0 / QRUV 7.3217.0 / QRUV
Ursprung:
auxiliary contact Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO
controller ventilator -M7 7.3146.00660 7.3146.00660 7.3146.00660
LV300 / grey LV300 / grey LV300 / grey
outlet filter 7.2752.00030 7.2752.00030 7.2752.00030
GV300 / yellow GV300 / yellow GV300 / yellow
(option) 7.2752.00010 7.2752.00010 7.2752.00010
Rübsamen&Herr GV300 / grey GV300 / grey GV300 / grey
terminal strip -X11/-X12 7.7113.00090 7.7113.00090 7.7113.00090
Ersatz für:
Wieland 99.735.5333.8 99.735.5333.8 99.735.5333.8
terminal strip -X10 3x 7.3149.02600 / WKFN4 D2/2/35 --- 3x 7.3149.02600 / WKFN4 D2/2/35
(option K1) Wieland 7.3149.01830 / WKFN 4 SL/35 7.3149.01830 / WKFN 4 SL/35
Surge protective device -F86 --- --- 7.8669.00020
(option K1, C47) DGMU 3PY 480 3W+ G
Dehn 908319

Ersatz durch:
model air dryer ABT 165

04.09.2017
Gegner
Sitter
contactor -Q30/-Q31 7.8740.03010 7.8740.03010 7.8740.03010

Siemens 3RT2016-1JB41 3RT2016-1JB41 3RT2016-1JB41
Bearbeiter
fuse -33 FU 3x 7.3161.00320 3x 7.3161.00310 3x 7.3306.00010

Geprüft
Datum
Norm
(option T2) Gould ATDR 20 (20 A, 600 V) ATDR 15 (15 A, 600 V) ATDR 7 (7 A, 600 V)
fuse socket -11FU 7.3320.00060 7.3320.00060 ---
Name
Wöhner Class CC 3-pol 31297 Class CC 3-pol 31297

fuse -11FU 3x 7.3306.00010 3x 7.3306.00010 ---
Gould ATDR 7 (7 A, 600 V) ATDR 7 (7 A, 600 V)
Datum
transformer -T30 7.5452.00270 7.5452.00270 ---

(option T2) B 1102010 B 1102010
Block 3x 230/380/440//460 V, 5.5 A 3x 230/380/440//460 V, 5.5 A
C Änderung
b
a
c

901726 08 USE CSD 100/125 T 139
140
1 2 3 4 5 6 7 8
10AWG black -40FU -W17

L1 -X0 U1 600V 90°C 1 2 **** L11
/3.1
L2 **** V1 3 4 L12
/3.1
L3 W1 5 6 L13
/3.1
GRD rail **** GRD
/3.1
Feed line connection
see page 15
For field wiring: -33FU

1 2 L21
Use 75°C copper /5.1
3 4 L22
conductors only! control panel /5.1
13
5 6 L23
13.4
control cabinet /5.1

****
GRD rail
4AWG
green/yellow -W13 -W11
600V 90°C **** ****
CSD 100/125 T
-W13 12AWG
Operator Manual
unit frame **** green/yellow
Annex
600V 90°C
-W15
****
control cabinet control cabinet door
1
3
5
1
3
5
1
3
5
-Q1 -Q2 -Q3
Electrical Diagram
/2.3 /2.5 /2.4
2
4
6
2
4
6
2
4
6
-W14
****
8AWG
1
3
5
97
95
GRD rail
-B25
green/yellow

**** 600V 90°C
2
4
6
98
/2.4 96
main disconnect,
fuse supplied unit frame oil separator
by user -W19
****
GRD
W1 V2
V1 M U2
U1 3~ W2
ϑ
-M1
****
L1 L2 L3 GRD
**** performance-related components,
see: electrical component parts list
supply line cross-section and
fusing see operating manual s.b.c. = supplied by customer
Function: compressor motor

Group of function: input voltage power unit
c Datum 04.09.2017 wiring diagram =
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: power supply/power unit SC2 MCS SCSDX.T-U3056.00 15 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
901726 08 USE
+M1
95
21
-B25 -Q1 compressor motor
/1.3 3
96
22
-B60
Int. Int. Int. Pt100
7
6
10
X3 X3 X3
-K21 -K21 -K21
13
13.4
/9.4
DI_PA /9.4
DI 1.01 /9.4
DI 1.02
overload relay answerback signal -W145

compressor motor main contactor
CSD 100/125 T
Operator Manual
Annex
main contactor wye contactor delta contactor

-K21 -K21 -K21 Int. control cabinet
1
2
DOR 1.00 DOR 1.01 DOR 1.02 X7

/9.4 COM /9.4 COM /9.4 COM -K21 AIR_A AIR_B
7
6
5
X5 X5 X5
Electrical Diagram
Int. Int. Int. /9.4 AIR 1.03

temperature compressor motor
-X11 5
-W70
13
13
21
21
-Q1 -Q3 -Q2 -Q3
L1 1

-M7 3 4 5 4
14
14
22
22
M GRD
20W 1~
115V -W70
N
60Hz
A1
A1
A1
GRD1 GNYE
-X11 -Q1 -Q3 -Q2
2
-W70
A2
A2
A2
-X11 04 L02
/3.5
1 2 1 2 1 2
/1.3 /1.5 /1.4
3 4 3 4 3 4
/1.3 /1.5 /1.4
5 6 5 6 5 6
/1.3 /1.5 /1.4
13 14 13 14 13 14
2 3
21 22 21 22 21 22
5 5 4
31 32 31 32 31 32
/11.4
43 44 43 44 43 44
/11.5
Function: controller ventilator compressor motor

Group of function: wye-delta changeover
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: compressor motor SC2 MCS SCSDX.T-U3056.00 15 Bl.
141
142
1 2 3 4 5 6 7 8
L11 -X10 1 -X10 1 L11

/1.8 /7.1
L12 2 2 L12
/1.8 /7.1
L13 3 3 L13
/1.8
GRD GRD
/1.8 /5.1
14AWG 14AWG black
green/yellow 600V 90°C option C47
L1
L2
L3
GRD3
-X11 600V 90°C -F86
Canada only
12
L1
L2
L3
GRD
1
3
5
GNYE
-R4 14
13
control panel
13.4
11
-T14
L1'
L2'
L3'
230/460V GRD 14AWG black
in
in
in
11,6/5,5A 600V 90°C
out
out
out
L1
L2
L3
GRD
CSD 100/125 T
Operator Manual
/G
/G
-R14 control panel
2
4
6
Annex
-W28
12AWG Int.
4
7G14AWG
10
green/yellow X8
600V 90°C
GRD
600V 90°C -X10 -K21 DI_PB DI
U1
V1
W1
GRD
DCP
R2
DCN
/9.4 DI 1.11
1
3
5
+ - -
Electrical Diagram
-4FU -T4 control panel Surge protective device

7A AC
2
4
6
Class CC DC
SINAMICS
/4.2
14AWG black G120 -T4.0 contactor frequency converter -T4

600V 90°C DC
AC
-K21 DOR 1.03
/9.3 COM
4
X5
V2
U2
W2
GRD
machine power supply 230V Int.
A1
-W29 option K1
-T4 -K54
4G14AWG
A2
screened
1000V 90°C L02 -X11 02 L02
/2.6 /7.1
-M4
U
V
W
GRD
13 14
/4.6
21 22
M 31 32
3~ 43 44
-M4
2 hp
Function: vent motor Oil/air cooler - option K1
Group of function: power unit control
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: vent motor / option K1 SC2 MCS SCSDX.T-U3056.00 15 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
901726 08 USE
option K1
13
13.4
13
-K54
CSD 100/125 T
/3.5
Operator Manual
22AWG
14
Annex
blue
600V 90°C
1
2
3
4
34
10
11
9
28
69
5
6
7
8
16
17
-T4
Electrical Diagram
+10 V 0 V AI0+ AI0- DI AI1+ AI1- U24V GND DI DI0 DI1 DI2 DI3 DI4 DI5
OUT COM2 COM1
ON
OFF
RDY 64 7
frequency converter 32 6 1
AI 0/1 2
16 5 /8.6
8 4 3 P+
1 2
/3.5 SINAMICS CU240E-2 BF 4

-T4.0 4 3 /8.6
RS-485
I U 2 2 5 N-
BUS ADRESS
SAFE 1 1
W255 LiYCY
IN 0,5A 0 - 20 mA PTC/KTY BUS 2x24AWG
+24V 0V AO0+ AO0- + - AO1+ AO1- closed -T4
NC NO COM NO COM NC NO COM
31
32
12
13
14
15
26
27
18
19
20
21
22
23
24
25
Function: volt-free contacts

Group of function:
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: binary inputs/outputs SC2 MCS SCSDX.T-U3056.00 15 Bl.
143
144
1 2 3 4 5 6 7 8
L21
/1.8
L22
/1.8
L23
/1.8
GRD
/3.8
-W17
GRD2
10
GRD1
GRD2
10
without option T2 -X11 -X11 with option T2 -X11 -X11
****
only for power supplies
-W220
1
2
3
GNYE
460V 60Hz 14AWG black
7G14AWG
600V 90°C
600V 90°C -T30
GRD
13
230/460V
in
in
in
13.4
380/460V
out
out
out
****
4
5
6
14AWG black
1
3
5
CSD 100/125 T
600V 90°C -11FU
Operator Manual
1
3
5
1
3
5
-Q30 -F31 14AWG black
7A
Annex
/6.3 14AWG black 600V 90°C
2
4
6
Class CC
2
4
6
600V 90°C
****
I>> I>> I>>
2
4
6
14AWG black
Electrical Diagram
14AWG black
1
3
5
-F32 600V 90°C
1
3
5
1
3
5
600V 90°C -Q30 -F31

/6.3 14AWG black
1
3
5
-Q31
2
4
6
600V 90°C
**** /6.4
2
4
6
I>> I>> I>> ****
I>> I>> I>>
2
4
6

-W176
2
4
6
1
2
3
7
8
9
4
5
6
10
11
GNYE
12G16AWG
14AWG black
1
3
5
500V 70°C -F32

600V 90°C
1
3
5
1) -Q31
1
2
3
GRD1
7
8
9
GRD1
4
5
6
GRD2
10
-X32 -X32 -X32 -X32 **** /6.4
2
4
6
I>> I>> I>>

2
4
6
-W170 -W172 -W171 -W176

1
2
3
7
8
9
4
5
6
10
11
GNYE
4G16AWG 4G18AWG 4G18AWG 12G16AWG
U
V
W
GRD
U
V
W
GRD
U
V
W
GRD
500V 70°C 500V 70°C 500V 70°C 500V 70°C
-M30 M -M32 M -M31 M 1)

1
2
3
GRD1
7
8
9
GRD1
4
5
6
GRD2
10
3~ 3~ 3~ -X32 -X32 -X32 -X32

overload protection
-W170 -W172 -W171
4G16AWG 4G18AWG 4G18AWG
U
V
W
GRD
U
V
W
GRD
U
V
W
GRD
500V 70°C 500V 70°C 500V 70°C

1) distribution terminal box in the dryer
-M30 M -M32 M -M31 M
3~ 3~ 3~
overload protection
Function: compressor motor with overload protection vent motor 2 vent motor 1 compressor motor with overload protection vent motor 2 vent motor 1
Group of function: power unit air dryer
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: air dryer SC2 MCS SCSDX.T-U3056.00 15 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
2L+ -X12 1 2L+

/8.4 /10.2
1
-W177
901726 08 USE
-X32 13 -X32 14 -X32 13 -X32 12 -X32 14
3
-W174 -W173 -W178 -W80
-B30 -B31 -B33
CO
-K34
P P P -B39
6
NO
>21 bar >7,5 bar >0,4bar
4
-W174 -W173 -W178 -W80
13
Pt100
15
16
17
18
13.4
-X32 -X32 -X32 -X32
6
3
4
5
-W177 -W177 -W177 -W177
9
7
safety air pressure switch -X12 -X12
Refrigerant compressor (Pressure limiter)
CSD 100/125 T
Operator Manual
-K21 -K21 Int. Int.
8
3
DOR 1.04 DI 1.08 X8 X3 -W118
Annex
/9.4 /9.4 -K21 -K21
2
1
7
X5 X8 DI 1.09 DI 1.05
/9.4 /9.4
Int. Int.
pressure switch condensate drain
6
5
-X12 -X12
Electrical Diagram
(Gassing pressure) Ext.

1
2
3
-K34 X15
8
-X12 ECO-DRAIN 31 NC
-K21 AIR_A Shield AIR_B
NO AIR 1.01
/9.4
13
-Q30 -W80 6
CO temperature probe

3
(pressure dew point)
14
1 L/+
-X32 11 2 N/-
-X32 GRD3
2
GNYE
-W177
A1
A1
-Q30 -Q31
GRD1
-X12
A2
A2
2L- -X12 02 -X12 01 -X12 03 2L-
/8.4 /10.2
16AWG green/yellow
1 2 1 2
/5.5 /5.7 600V 90°C
3 4 3 4
/5.5 /5.7 -X12 GRD1
5 6 5 6
/5.5 /5.7
13 14 13 14
4
Function:
Group of function: air dryer
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: air dryer control SC2 MCS SCSDX.T-U3056.00 15 Bl.
145
146
1 2 3 4 5 6 7 8
L11 -X11 1 -X11 2 -X11 3 L01

/3.8 /8.1
L12
/3.8
-W17
14AWG black
TW
**** -M5
600V 90°C
option K1: 5
18AWG red
TW
-W46.1
2
4
6
600V 90°C
1
3
5
11
-1FU -2FU -3FU -Q4 -S1 21
**** **** **** option K2/K9:
13
5
13.4
Ext.
2
4
6
14AWG black
1
3
5
22
Class CC Class CC Class CC
1
2
3
12
600V 90°C X25 EMERGENCY STOP
-K21 DI_PA DI
14AWG
14AWG black DI 1.03
black /9.4
CSD 100/125 T
600V 90°C
Operator Manual
600V 90°C overload vent motor Int.
9
8
X3
Annex
14AWG DI_PA DI
starter vent motor
-K21
green/yellow
4
-T11 -X11 6 -X11 DI 1.00

600V 90°C -K21 /9.4
DOR 1.03
EMERGENCY STOP
/9.4 COM
Electrical Diagram
4
X5
control panel **** 115V Int.
1
-W46
L1
option K1: -M5 -K21
model-specific DOR COM

18 AWG white M
electrical diagram 165W /9.4 COM
600V 90°C 1~
see page 13 115V
9
8
option K2/K9: -W46 X5
N
60Hz Int.
14 AWG grey
GRD2 GNYE
A1
600V 90°C -X11
-Q4
2
-W46
A2
L02 -X11 04 -X11 01 -X11 03 L02

/3.6 /8.1
16AWG
TW TW
green/yellow 5
1 2
600V 90°C 5
GRD1
-X11 3 4
5
5 6
5
option K2/K9

Function: 115V/1ph/60Hz compressor unit ventilator EMERGENCY STOP

Group of function: control voltage tapping option K2/K9 safety chain
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control voltage tapping SC2 MCS SCSDX.T-U3056.00 15 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
L01 -X11 3 L01
901726 08 USE
/7.8
L02 03 L02
/7.8
-K20
MCS
X5
14AWG
SD card
green/yellow
13
13.4
600V 90°C
X6
option COM-Module RS485-FC Ethernet IO-Bus
CSD 100/125 T
control panel X4 X3 X1 X2
Operator Manual
9 8 7 6 5 4 3 2 1
Annex
N P
P+ /4.8
-W81
/4.8
Electrical Diagram
N- 3x2x24AWG
screened
-T21
-K21

1) X1
100- + -X12 2 2L+ I/O-BUS
/6.1 /9.4 X4
240V~ +
L1 3 L+
-
24V= 2 L-
IOM 1
N - 2L-
/6.1 1 FE
2,5A -
short circuit proof I/O-BUS
14AWG
X2
green/yellow
600V 90°C
control panel
1) Reset: Switch off L1 for 3 minutes
Function: 24V DC
Group of function: control voltage
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: power supply unit SC2 MCS SCSDX.T-U3056.00 15 Bl.
147
148
1 2 3 4 5 6 7 8
-K21 IOM1 inside

11 1
DI_PA AII_PA
10 2
/2.3 DI_PA AII 1.02
X6
9 3
/7.7 DI_PA AII_GND
8
/7.7 DI 1.00
7
13
/2.4 1
13.4
DI 1.01 AIR 1.03 /2.7

6
X7
/2.5 DI 1.02 2
X3
AIR 1.03 /2.7 -K21
5
DI 1.03
4
/10.7 DI 1.04 1
IOM1 external
CSD 100/125 T
3 DI_PB
Operator Manual
/6.6 DI 1.05 2
2 DI_PB /10.1 AII 1.00 X11 X22 DI 1.00
Annex
DI 1.06 3
1 DI_PB /10.2 AII 1.01 X12 X23 DI 1.01
DI 1.07 4
DI_PB /3.7 AII 1.02 X13 X24 DI 1.02
8 5
DOT 1.01 DI_PB /10.3 AIR 1.00 X14 X25 DI 1.03 /7.5
7 6
Electrical Diagram
M24 DI_PB /6.8 AIR 1.01 X15 X26 DI 1.04
X8
6 7
/10.4 DOT 1.02 DI 1.08 /6.2 /10.4 AIR 1.02 X16 X27 DI 1.05
5 8
M24 DI 1.09 /6.4 AIR 1.03 X17 X28 DI 1.06 /10.5
X4
4 9
FE DI 1.10 DI 1.08 X18 X29 DI 1.07
3 24V 10
/8.6 L+ DI 1.11 /3.7 DI 1.09 X19 X30 DOT 1.00 /10.1

2 11
/8.6 0V L- DI 1.12 /10.6 DI 1.14 X20 X31 DOT 1.01
1 12
/8.6 FE DI 1.13 /10.7 DI 1.15 X21 X32 DOT 1.02
9 1
/7.7 DOR COM DOR 1.05
8 2
DOR COM DOR COM
7 3
/2.3 DOR 1.00
6 4
/2.4 DOR 1.01 DOR 1.06
5 5
/2.5
X9
DOR 1.02 DOR COM
X5
4 6
/3.5 /7.5 DOR 1.03
3 7
DOR 1.07
2 8
/6.2 DOR COM DOR COM
1 9
/6.2 DOR 1.04
Function:
Group of function:
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: IO-module/configuration SC2 MCS SCSDX.T-U3056.00 15 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
-B1 -B4 -B40 -B43
901726 08 USE
P P
1
1
1
-B5 -B3 -B2
4...20mA 4...20mA
Pt100 Pt100 P P P
3
2
2
- + - +
>-0,05 bar >Δp 1,5 bar >1,0 bar
2
1
2
1
1
4
-W115 -W116 -W117 -W150 -W106 -W105 -W104
13
13.4
CSD 100/125 T
Ext. Ext. Ext. Ext. Ext. Ext. Ext.
Operator Manual
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
1
2
3
X11 X12 X14 X16 X28 X20 X21

Annex
-K21 AII AII_PA GND -K21 AII AII_PA GND -K21 AIR_A Shield AIR_B -K21 AIR_A Shield AIR_B -K21 DI_PA DI -K21 DI_PB DI -K21 DI_PB DI
/9.4 AII 1.00 /9.4 AII 1.01 /9.4 AIR 1.00 /9.4 AIR 1.02 /9.4 DI 1.06 /9.4 DI 1.14 /9.4 DI 1.15
air main pressure package internal pressure airend discharge temperature inlet temperature air filter oil filter direction of rotation
Electrical Diagram
control valve
-K21 DOT 1.00
2L+ -X12 3 -X12 1 -X12 2 2L+
/9.4 DOT M24 /6.8

2L- 03 01 2L-
/6.8
1
2
3
X30
Ext.
3
control valve oil temperature -W78

-K21 DOT 1.02
CO
-K10
/9.4 -K10
-W113 6
ECO-DRAIN 31 NC
6
X4
NO
Int.
4
NO
-X12 10 -W78 7
CO -X12 4
1(+)
2(-)
2
1
3
-W141
1 L/+
Int.
LS
MM
1
2
4
2 N/- X3
-M20
-K21
-K1 M DI 1.04
- /9.4
condensate drain centrifugal separator
PWM
Function:
Group of function:
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: sensors/actuators SC2 MCS SCSDX.T-U3056.00 15 Bl.
149
150
1 2 3 4 5 6 7 8
13
13.4
volt-free contacts
User's connection
CSD 100/125 T
Operator Manual
Annex
31
43
-Q1 -Q1
Electrical Diagram
/2.3 /2.3
32
44
15
16
17
-X11 -X11 -X11

max. 250V AC/24V DC, 3A
For Field Wiring:

Use Copper Conductors Only!
Connect Control Device Only!
all non-designated conductors,

16 AWG orange 600V 90°C
Function: compressor motor running

Group of function: volt-free contacts
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: volt-free contacts SC2 MCS SCSDX.T-U3056.00 15 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
901726 08 USE
Inputs/outputs for use by others possible connections for AII 1.02
** pre-allocated
*** available for use 4-wire connection
example connections 2-wire connection
L+ L-
?
?
4...20mA 4...20mA
out -
13
+ -
13.4
CSD 100/125 T
Operator Manual
Annex
Int. Int. Int. Int. Int. Int.
1
3
9
5
6
1
2
3
1
2
3
11
11
12
X3 X8 X8 X8 X6 X6
-K21 DI_PA DI -K21 DI_PB DI -K21 DI_PB DI -K21 DI_PB DI -K21 AII_PA AII GND -K21 AII_PA AII GND
Electrical Diagram
DI 1.07 DI 1.10 DI 1.12 DI 1.13 AII 1.02 AII 1.02

*** *** Remote ON/OFF ** load/idling ** 4-20mA 4-20mA, 18V DC
Ri = 200Ω Ri = 200Ω
digital inputs, User's connection
18V DC/7mA analog inputs, User's connection

max. cable length 100m max. cable length 30m
digital output, User's connection digital output, User's connection

max. 250V AC/24V DC, 1A 24V DC/0,3A
max. cable length 100m max. cable length 30m
control ON ** FAILURE ** pressure dew point high ** ***

-K21 DOR 1.05 -K21 DOR 1.06 -K21 DOR 1.07 -K21 DOT 1.01
DOT M24
8
2
1
5
4
8
7
7
X9 X9 X9 X4
Int. Int. Int. Int.
For Field Wiring:

Use Copper Conductors Only!
Connect Control Device Only!
Function:
Group of function:
a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: inputs-/outputs SC2 MCS SCSDX.T-U3056.00 15 Bl.
151
152
1 2 3 4 5 6 7 8
primary
230V
L1
L2
diagram 1 primary L1/L2 diagram 3
0
208V
230V
460V
-T11 -T11
0
220V
230V
240V
0
220V
230V
240V
primary power connection
13
13.4
L1 L2
230V 0 230V
0
460V 0 460V
115V
0
0
CSD 100/125 T
Operator Manual
115V
115V
115V
Annex
secondary
secondary
L02
-F11:5
L02
-F11:5
230V
Electrical Diagram
primary
diagram 2
L1
L2
jumper

-T11 primary between:
1
31
32
33
34
35
36
37
38
2
380V 31-38
0
0
115V
115V
115V
L02
-3FU
secondary

a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: transformer diagrams SC2 MCS SCSDX.T-U3056.00 15 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
fig. 1: Handling: Control line terminal
901726 08 USE
13
13.4
CSD 100/125 T
Operator Manual
Annex
Electrical Diagram
fig. 2: Handling: Supply terminal Wago

a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Handling: Terminals SC2 MCS SCSDX.T-U3056.00 15 Bl.
153
154
1 2 3 4 5 6 7 8
fig. 10: Feed line connection fig. 11: Feed line connection
13
13.4
CSD 100/125 T
Operator Manual
Annex
Electrical Diagram

a Geprüft Gegner
D Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: Feed line connection SC2 MCS SCSDX.T-U3056.00 15 Bl.
901726 08 USE
155 CSD 100/125 T 901726 08 USE
Rotary screw compressor Operator Manual
c
a
b
destination destination
cable-no. terminal strip cable-no.
inside external
H Änderung
link
location
connection
connection
jumper wire
terminal-no.
Datum
name of device
name of device
terminal legend
Name
-W78 4x18AWG 600V 90°C
-W70 3G18AWG 500V 70°C

-W46 3G16AWG 500V 70°C
-W28 7G14AWG 600V 90°C
-W220 7G14AWG 600V 90°C

-W177 7G18AWG 500V 70°C
-W141 3x18AWG 600 V 90°C
1) compressor motor running
-W176 12G16AWG 500V 70°C

-W176 12G16AWG 500V 70°C
Norm
Datum
Geprüft
Bearbeiter
volt-free contacts, User's connection
terminal strip: -X11

total 22 terminals
Sitter
Gegner
-3FU 6 1 /7.4
04.09.2017
-T11 0 01 /7.2
2) -Q4 1 2 /7.5
3) -K54 A2 02 /3.6 -Q4 A2 2)
-S1 11 3 /7.7 -T21 L1
2
2) -M5 N 03 /8.2 -T21 N

Ersatz durch:
-S1 12 4 /7.7 -K21-X5 9

-M7 N 04 /7.2 .
2 1
-M7 L1 5 /2.2 -Q1 13

3) option K1
2) -M5 L1 6 /7.5 -Q4 2 2)

2) option K2/K9
9
10
11
-X32 10 10 /5.8 -X32 10

GN
YE
-M7 GRD GRD1 /7.2 .

GN
YE
5) -T30 GRD GRD1 /5.6

GN
Ersatz für:
YE
-X32 GRD2 GRD2 /5.8

GN
YE
2) -M5 GRD GRD2 /7.5 .

GRD3
4) option K1 - machine power supply 230V
GN
YE
4) -T14 GRD GRD3 /3.2

-Q1 43 15 /11.4 1)
-Q1 32 16 /11.4 1)
-Q1 44 17 /11.5 1)
18
Ursprung:
total 16 terminals
GN
YE
-X32 GRD3 GRD1 /6.5
5) option T2
GRD1 /6.6
6) option C47 -
-X32 12 1 /6.5 -K10 L/+
1 2
-X32 11 01 /6.5 -K10 N/-
1 2 3
-T21 + 2 /8.4 -K10 CO

-T21 - 02 /6.3 -Q30 A2
-M20 LS 3 /10.3
2 1
-M20 MM 03 /6.6 .
4
-K21-X3 4 4 /10.7 -K10 NO
terminal connection
-X32 16 5 /6.4 -Q30 13
Canada only - machine power supply 460V
-X32 15 6 /6.3 -K21-X8 7
terminal strip -X11,-X12,-X10

3 6 5
-X32 18 7 /6.6 -K21-X3 3
8 /6.3 -K21-X5 2
4
-X32 17 9 /6.4 -K21-X8 8

3
-M20 PWM 10 /10.4 -K21-X4 6
11
4) terminal strip: -X10
total 6 terminals
-40FU 2 1 /3.2 -1FU 2
1
-T14 in 1 /3.2
-40FU 4 2 /3.2 -2FU 4
SC2 MCS
3
-T14 in 2 /3.2
-40FU 6 3 /3.2
5
-T14 in 3 /3.2
6) terminal strip: -X10
total 7 terminals
-F86 /G GRD /3.7
-40FU 2 1 /3.6 -1FU 2
1 /3.6 -F86 L1
-40FU 4 2 /3.6 -2FU 4
+
=
2 /3.6 -F86 L2
-40FU 6 3 /3.7
KCSDX.T-U3056.00
GNYE = green/yellow
3 /3.7 -F86 L3
page
2
1
Bl.
Electrical Diagram 13.4
Annex 13
156
-W178 2x18AWG 500V 70°C
-W177 7G18AWG 500V 70°C GN 2 1 6 3 4 5
YE
cable-no.
-W176 12G16AWG 500V 70°C 1 2 3 4 5 6 GN
YE 7 8 9 10
-W172 4G18AWG 500V 70°C GN
YE
-W80 4x18AWG 600V 90°C 3
13
13.4
2
4
6
2
4
6
2
4
6
1
6
5
9
7
10
01
CO
connection
GRD
GRD2
GRD1
inside
CSD 100/125 T
destination
Operator Manual
name of device
-Q30
-Q30
-Q30
-M32
-Q31
-Q31
-Q31
-X11
-F32
-F32
-F32
-X11
-X12
-X12
-X12
-B33
-K34
-X12
-X12
-X12
-X12
Annex
location
/5.5
/5.6
/5.6
/5.7
/5.7
/5.7
/5.7
/5.8
/5.6
/5.6
/5.7
/5.8
/6.5
/6.5
/6.5
/6.3
/6.4
/6.3
/6.4
/6.4
/6.6
jumper wire
Electrical Diagram
terminal legend
total 22 terminals
terminal strip
link

terminal-no.
1
2
3
GRD1
4
5
6
GRD2
7
8
9
10
GRD3
11
12
13
14
15
16
17
18

V
V
V
U
U
U
W
W
W
10
NO
connection
N/-
L/+
GRD
GRD
external
destination
name of device
-M30
-M30
-M30
-M30
-M31
-M31
-M31
-M31
-M32
-M32
-M32
-X11
-K34
-K34
-B30
-B31
-B30
-B31
-B33
-K34
-W80 4x18AWG 600V 90°C 2 1 4
-W170 4G16AWG 500V 70°C 1 2 3 GN
YE
-W171 4G18AWG 500V 70°C 1 2 3 GN
YE
-W172 4G18AWG 500V 70°C 1 2 3
-W173 2x18AWG 500V 70°C
cable-no.
-W174 2x18AWG 500V 70°C
-W176 12G16AWG 500V 70°C 11
-W178 2x18AWG 500V 70°C
GNYE = green/yellow
c Datum 04.09.2017 terminal connection =

a Geprüft Gegner
H Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: terminal strip -X32 SC2 MCS KCSDX.T-U3056.00 2 Bl.
901726 08 USE
1 2 3 4 5 6 7 8
901726 08 USE
24V=
machine power supply:

380V 60Hz
-T21 -T11
-X12
-X11
24V=
460V 60Hz
24V=
13
13.4
2)
-Q4
-Q30 -Q31 -F32 -F31
-1FU
-2FU
-3FU
-11FU
-11FU
-11FU
-K54 -R4
CSD 100/125 T
Operator Manual
1)
1) 3)
Annex
-F86
-X10
-33FU
Electrical Diagram
995
24V=
-40FU 4)
1130
W1
W1
V1

V1
U1
U1
-X0
-Q1 -Q2 -Q3
-K21 1) option K1
-T4
GRD rail
IOM 1 2) option K2/K9

-B25 -R14
3) machine power supply 380V
4) option K1 / C47 -
1) machine power supply 460V, Canada only
24V=
945
1134 The components are performance-related

1274 and not shown to scale.
c Datum 04.09.2017 lay-out =

a Geprüft Gegner
I Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control panel 380V/460V SC2 MCS ACSDX.T-U3056.00 2 Bl.
157
158
1 2 3 4 5 6 7 8
24V=
-T21 -T11
-X12
-X11
24V=
machine power supply:
230V 60Hz
24V=
13
13.4
2)
-Q4
-Q30 -Q31 -F32 -F31 -33FU
-4FU
-4FU
-4FU
-1FU
-2FU
-3FU
-11FU
-11FU
-11FU
-K54 -R4
CSD 100/125 T
Operator Manual
1)
1) 1)
Annex
-X10
-40FU 1)
Electrical Diagram
995
24V=
W1
1130
W1
V1
V1

U1
U1
-Q1 -Q2 -X0

-Q3
GRD rail
-K21 -T4
-B25
IOM 1 -R14
1) option K1
2) option K2/K9
1)
24V=
945
The components are performance-related

and not shown to scale.
1134
1274
dc Datum 04.09.2017 lay-out =
a Geprüft Gegner
I Änderung Datum Name Norm Ersatz durch: Ersatz für: Ursprung: control panel 230V SC2 MCS ACSDX.T-U3056.00 2 Bl.
901726 08 USE

Manual de Servicio CSD 125T

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Manual de Servicio CSD 125T

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Operator Manual

Rotary screw compressor

1 Regarding this Document

Operator Manual Rotary screw compressor

3.10 Warranty ........................................................................................................................... 33

Operator Manual Rotary screw compressor

8.1.2 Switching off ....................................................................................................... 64

Operator Manual Rotary screw compressor

12.2 Packing ............................................................................................................................ 112

Operator Manual Rotary screw compressor

Operator Manual Rotary screw compressor

Operator Manual Rotary screw compressor

Tab. 1 Danger levels and their definition (personal injury) .................................................................... 1

Operator Manual Rotary screw compressor

Tab. 55 MODULATING control: Setting the shut-off valve ...................................................................... 61

Operator Manual Rotary screw compressor

1 Regarding this Document

1.2 Further documents

Missing documents can be requested from KAESER.

1.4 Symbols and labels

Tab. 1 Danger levels and their definition (personal injury)

Operator Manual Rotary screw compressor

The type and source of the imminent danger is shown here!

1.4.2 Potential damage warnings

Warning notices for damages are identified by their signal term.

Tab. 2 Danger levels and their definition (damage to property)

The type and source of the imminent danger is shown here!

➤ Carefully read and fully comply with warnings against damages.

1.4.3 Other alerts and their symbols

Operator Manual Rotary screw compressor

Further information Further subjects are introduced here.

Operator Manual Rotary screw compressor

The nameplate is located on the outside of the machine:

➤ Enter here the nameplate data as a reference:

Option Option code Available?

Operator Manual Rotary screw compressor

Option Option code Available?

CSD 100 CSD 125

Tab. 5 Machine weight

Operator Manual Rotary screw compressor

2.5 Ambient conditions

Tab. 7 Ambient conditions

CSD 100 CSD 125

Safety relief valve activating pressure [psig]:

Maximum working pres‐ CSD 100 CSD 125

Tab. 9 Safety relief valve activating pressure

Operator Manual Rotary screw compressor

2.8 Free air delivery (FAD)

Maximum working pres‐ CSD 100 CSD 125

Tab. 10 Free air delivery

2.9 Cooling Oil Recommendation

2.9.1 Basic Information

2.9.2 KAESER Lubricants

Operator Manual Rotary screw compressor

Specialty KAESER LUBRICANTS

2.10 Cooling oil charge

Option K1 Air cooling

CSD 100 CSD 125

Tab. 11 Cooling oil charge (Option K1)

Option K2 Water cooling (plate-type heat exchanger)

CSD 100 CSD 125

Tab. 12 Cooling oil charge (Option K2)

Operator Manual Rotary screw compressor

Option K9 Water cooling (bundled pipe heat exchanger)