Airtower With SC2 9 - 6917 - 43USE

Operator Manual
Screw Compressor
AIRTOWER 3C–7.5C Tri-Voltage

9_6917 43 USE
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Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
www.kaeser.com
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Original instructions
/KKW/SSXC 2.23 en Z1 SBA-SCHRAUBEN-TRI-VOLTAGE-AC-SC2IO
/KKW/SSC 2.13 Z1
20220712 083349
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
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2.2 Options ............................................................................................................................. 4
2.3 Weight .............................................................................................................................. 5
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2.4 Temperature ..................................................................................................................... 5
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2.5 Ambient conditions ........................................................................................................... 6
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2.6 Ventilation ........................................................................................................................ 6
2.7 Pressure ........................................................................................................................... 7
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2.8 Air receiver .......................................................................................................................
2.9 Flow rate (constant delivery volume relative to intake conditions) ...................................
7
7
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2.10 Cooling Oil Recommendation .......................................................................................... 8
2.10.1 Basic Information ................................................................................................ 8
2.10.2 KAESER Lubricants ............................................................................................ 8
2.11 Cooling oil charge quantity ............................................................................................... 9
2.12 Motors and power ............................................................................................................ 9
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2.12.1 Compressor motor: ............................................................................................. 9
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2.13 Sound emission ................................................................................................................ 10

2.14 Power Supply ................................................................................................................... 10
2.15 Power Supply specifications ............................................................................................ 11
2.16 Refrigerated dryer ............................................................................................................ 12
2.16.1 Power supply specifications ................................................................................ 13
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3 Safety and Responsibility

3.1 Basic instructions ............................................................................................................. 14
3.2 Specified use .................................................................................................................... 14
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3.3 Improper use .................................................................................................................... 14

3.4 User's Responsibilities ..................................................................................................... 14
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3.4.1 Observe statutory and universally accepted regulations .................................... 14

3.4.2 Qualified personnel ............................................................................................. 15
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3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 15

3.5 Dangers ............................................................................................................................ 15
3.5.1 Safely dealing with sources of danger ................................................................ 16
3.5.2 Safe machine operation ...................................................................................... 18
3.5.3 Organizational Measures .................................................................................... 20
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3.5.4 Danger Areas ...................................................................................................... 20

3.6 Safety devices .................................................................................................................. 20
3.7 Working life of safety functions ........................................................................................ 21
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3.8 Safety signs ...................................................................................................................... 21

3.9 Emergency situations ....................................................................................................... 23
3.9.1 Correct fire fighting ............................................................................................. 23
3.9.2 Treating injuries from handling cooling oil .......................................................... 23
3.9.3 Injury from Handling Refrigerant ......................................................................... 24
3.10 Warranty ........................................................................................................................... 24
3.11 Environmental protection ................................................................................................. 25
4 Design and Function
4.1 Enclosure ......................................................................................................................... 26
Operator Manual Screw Compressor

9_6917 43 USE AIRTOWER 3C–7.5C Tri-Voltage i
Contents
4.2 Machine overview ............................................................................................................ 27

4.3 Refrigerated dryer ............................................................................................................ 28
4.4 Air receiver ....................................................................................................................... 28
4.5 Floating relay contacts ..................................................................................................... 28
4.6 Options ............................................................................................................................. 28
4.6.1 SIGMA CONTROL 2 : Connection to control technology ................................... 29
4.6.2 Machine mountings ............................................................................................. 29
4.7 Operating modes and control modes ............................................................................... 29
4.7.1 Machine operating modes .................................................................................. 29
4.7.2 START-STOP control ......................................................................................... 30
4.8 Refrigerated dryer control modes ..................................................................................... 30
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4.9 Safety devices .................................................................................................................. 30
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4.10 Operating panel SIGMA CONTROL 2 ............................................................................. 31
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5 Installation and Operating Conditions
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5.1 Ensuring safety ................................................................................................................ 34
5.2 Installation conditions ....................................................................................................... 34
5.2.1
5.2.2
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Determining location and clearances ..................................................................
Ensuring adequate ventilation ............................................................................
34
35
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5.3 Operating the machine in a compressed air system ........................................................ 36
6 Installation
6.1 Ensuring safety ................................................................................................................ 37
6.2 Reporting Transport Damage ........................................................................................... 38
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6.3 Connecting the machine to the compressed air network ................................................. 38
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6.4 Connecting the condensate drain .................................................................................... 38

6.5 Connecting the external pressure transducer .................................................................. 40
6.6 Refrigerated dryer: Connecting the transformer according to the power supply. ............. 41
6.7 Making the Power Supply Connection ............................................................................. 41
6.7.1 Changing main voltage connections ................................................................... 41
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6.7.2 Connect power to the machine ........................................................................... 42

6.8 Options ............................................................................................................................. 43
6.8.1 Anchoring the machine ....................................................................................... 43
7 Initial Start-up
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7.1 Ensuring safety ................................................................................................................ 44

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7.2 Instructions to be observed before commissioning .......................................................... 45

7.3 Checking installation and operating conditions ................................................................ 45
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7.4 Setting the overload protection relay ................................................................................ 46

7.5 Pouring cooling oil into the airend .................................................................................... 46
7.6 Starting the machine for the first time .............................................................................. 47
7.7 Setting the set point pressure .......................................................................................... 47
7.8 Setting the display language ............................................................................................ 47
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8 Operation
8.1 Switching on and off ......................................................................................................... 49
8.1.1 Switching on ....................................................................................................... 49
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8.1.2 Switching off ....................................................................................................... 49

8.2 Switching off in an emergency and switching on again .................................................... 50
8.3 Switching on and off from a remote control center ........................................................... 50
8.4 Using the timer for switching on and off ........................................................................... 51
8.5 Interpreting operation messages ...................................................................................... 52
8.6 Acknowledging alarm and warning messages ................................................................. 52
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 54
9.2 Other Faults ..................................................................................................................... 54

ii AIRTOWER 3C–7.5C Tri-Voltage 9_6917 43 USE
Contents
10 Maintenance
10.1 Ensuring safety ................................................................................................................ 56
10.2 Following the maintenance plan ....................................................................................... 57
10.2.1 Logging maintenance work ................................................................................. 57
10.2.2 Resetting maintenance interval counters ............................................................ 57
10.2.3 Regular maintenance tasks ................................................................................ 57
10.2.4 Cooling oil changing interval ............................................................................... 59
10.2.5 Regular service tasks ......................................................................................... 59
10.3 Clean or replace the filter mat .......................................................................................... 59
10.4 Cooler maintenance ......................................................................................................... 60
10.5 Change the air filter .......................................................................................................... 61
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10.6 Compressor motor maintenance ...................................................................................... 62
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10.7 Changing the drive belt .................................................................................................... 62
10.8 Checking the safety relief valve activating pressure ........................................................ 63
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10.8.1 Checking the compressor safety relief valve ...................................................... 64
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10.8.2 Checking the air receiver safety relief valve ....................................................... 64
10.8.3 Performing the test ............................................................................................. 65
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10.9 Checking the overheating safety shutdown function ........................................................ 66
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10.10 Testing the EMERGENCY STOP push button ................................................................. 66
10.11 Checking the cooling oil level ........................................................................................... 67
10.12 Venting the machine (depressurizing) .............................................................................. 67
10.13 Replenishing cooling oil ................................................................................................... 69
10.13.1 Venting the machine (depressurizing) ................................................................ 70
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10.13.2 Topping off with cooling oil and test run ............................................................. 71
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10.14 Changing the cooling oil ................................................................................................... 71

10.15 Changing the oil filter ....................................................................................................... 74
10.16 Changing the oil separator cartridge ................................................................................ 76
10.17 Maintaining the refrigerated dryer .................................................................................... 77
10.17.1 Cleaning the refrigerant condenser .................................................................... 77
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10.17.2 Maintaining the condensate drain ....................................................................... 78

10.18 Air receiver maintenance ................................................................................................. 80
10.19 Documenting maintenance and service work .................................................................. 82
11 Spares, Operating Materials, Service
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11.1 Note the nameplate .......................................................................................................... 83

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11.2 Ordering spare parts and operating fluids/materials ........................................................ 83

11.3 KAESER AIR SERVICE ................................................................................................... 83
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11.4 Replacement parts for service and repair ........................................................................ 84

12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 89
12.1.1 Temporary decommissioning .............................................................................. 89
12.1.2 Long-term decommissioning ............................................................................... 89
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12.2 Packing ............................................................................................................................ 89

12.3 Storage ............................................................................................................................. 90
12.4 Transport .......................................................................................................................... 90
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12.4.1 Safety .................................................................................................................. 90

12.4.2 Transport with a forklift truck ............................................................................... 90
12.4.3 Transport with a crane ........................................................................................ 91
12.5 Disposal ........................................................................................................................... 93
12.5.1 Battery disposal in accordance with local environmental regulations. ................ 93
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 94
13.2 Dimensional Drawing ....................................................................................................... 100
13.3 Electrical Diagram ............................................................................................................ 102

9_6917 43 USE AIRTOWER 3C–7.5C Tri-Voltage iii
Contents
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iv AIRTOWER 3C–7.5C Tri-Voltage 9_6917 43 USE
List of Illustrations
Fig. 1 Maximum relative humidity of inlet air ........................................................................................ 6

Fig. 2 Three-phase star (wye system); 4 wire; center point solidly grounded ...................................... 10
Fig. 3 Three-phase star (wye system); 3 wire; grounded center point solidly grounded ...................... 10
Fig. 4 Location of safety signs .............................................................................................................. 21
Fig. 5 Enclosure overview .................................................................................................................... 26
Fig. 6 Machine overview ....................................................................................................................... 27
Fig. 7 Refrigerated dryer ...................................................................................................................... 28
Fig. 8 Machine mountings .................................................................................................................... 29
Fig. 9 Keys – overview ......................................................................................................................... 31
Fig. 10 Indicators overview ..................................................................................................................... 32
Fig. 11 RFID reader ................................................................................................................................ 33
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Fig. 12 Recommended machine placement and dimensions [in] ........................................................... 35
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Fig. 13 Compressed pipework ................................................................................................................ 38
Fig. 14 Connecting the condensate drain ............................................................................................... 40
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Fig. 15 Inlet valve filling port ................................................................................................................... 46
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Fig. 16 Switching on and off ................................................................................................................... 49
Fig. 17 Switching off in an emergency ................................................................................................... 50
Fig. 18
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Switching on and off from a remote control center ..................................................................... 50
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Fig. 19 Using the timer for switching on and off ..................................................................................... 51
Fig. 20 Acknowledging messages .......................................................................................................... 52
Fig. 21 Filter mat .................................................................................................................................... 60
Fig. 22 Oil cooler .................................................................................................................................... 61
Fig. 23 Change the air filter .................................................................................................................... 62
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Fig. 24 Drive belt maintenance ............................................................................................................... 63
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Fig. 25 Compressor: Checking the safety relief valve ............................................................................ 64

Fig. 26 Air receiver: Check the safety relief valve .................................................................................. 65
Fig. 27 Testing the EMERGENCY STOP push button ........................................................................... 66
Fig. 28 Checking the cooling oil level ..................................................................................................... 67
Fig. 29 Venting the machine ................................................................................................................... 68
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Fig. 30 Replenishing cooling oil .............................................................................................................. 69

Fig. 31 Changing the cooling oil, oil separator tank ............................................................................... 72
Fig. 32 Removing/replacing the belt guard ............................................................................................. 73
Fig. 33 Changing the oil filter .................................................................................................................. 75
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Fig. 34 Changing the oil separator cartridge .......................................................................................... 76

Fig. 35 Refrigerated dryer ...................................................................................................................... 77
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Fig. 36 Checking the condensate drain .................................................................................................. 78

Fig. 37 Changing the service unit ........................................................................................................... 79
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Fig. 38 Air receiver maintenance ............................................................................................................ 80

Fig. 39 Transport with a forklift truck ...................................................................................................... 91
Fig. 40 Transporting with a crane ........................................................................................................... 92
Fig. 41 Battery labelling .......................................................................................................................... 93
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9_6917 43 USE AIRTOWER 3C–7.5C Tri-Voltage v
List of Illustrations
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vi AIRTOWER 3C–7.5C Tri-Voltage 9_6917 43 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 Type label ................................................................................................................................... 4
Tab. 4 Options ....................................................................................................................................... 5
Tab. 5 Weight ........................................................................................................................................ 5
Tab. 6 Temperature ............................................................................................................................... 5
Tab. 7 Ambient conditions ..................................................................................................................... 6
Tab. 8 Ventilation ................................................................................................................................... 6
Tab. 9 Safety relief valve activating pressure ........................................................................................ 7
Tab. 10 Air receiver: Volume ................................................................................................................... 7
Tab. 11 Safety relief valve: Activating pressure ...................................................................................... 7
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Tab. 12 Flow rate [cfm] ............................................................................................................................ 7
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Tab. 13 Cooling oil charge quantity ......................................................................................................... 9
Tab. 14 Compressor motor ...................................................................................................................... 9
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Tab. 15 Compressor motor: Rated speed ............................................................................................... 9
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Tab. 16 Sound emission .......................................................................................................................... 10
Tab. 17 Supply 208V/3/60Hz ................................................................................................................... 11
Tab. 18
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Supply 230V/3/60Hz ................................................................................................................... 11
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Tab. 19 Supply 460V/3/60Hz ................................................................................................................... 11
Tab. 20 Model .......................................................................................................................................... 12
Tab. 21 Compressed air system .............................................................................................................. 12
Tab. 22 Refrigerant system ..................................................................................................................... 12
Tab. 23 Rated power supply 115V / 1ph / 60Hz ...................................................................................... 13
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Tab. 24 Danger Areas ............................................................................................................................. 20
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Tab. 25 Safety Signs ............................................................................................................................... 22

Tab. 26 Components ............................................................................................................................... 29
Tab. 27 Keys ........................................................................................................................................... 31
Tab. 28 Indicators .................................................................................................................................... 32
Tab. 29 RFID reader ................................................................................................................................ 33
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Tab. 30 Condensate line ......................................................................................................................... 39

Tab. 31 Condensate collecting line ......................................................................................................... 39
Tab. 32 Condensate collecting line: Line diameter .................................................................................. 39
Tab. 33 Voltage selection ........................................................................................................................ 41
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Tab. 34 Overload protection cutout settings. ........................................................................................... 42

Tab. 35 Re-commissioning after storage/standstill .................................................................................. 45
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Tab. 36 Installation conditions checklist .................................................................................................. 45

Tab. 37 Machine identification ................................................................................................................. 51
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Tab. 38 Remote control center identification ........................................................................................... 51

Tab. 39 Warning notice for timer control ................................................................................................. 51
Tab. 40 Other faults and actions ............................................................................................................. 54
Tab. 41 Warn others that the machine is being serviced. ....................................................................... 56
Tab. 42 Regular maintenance tasks ........................................................................................................ 58
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Tab. 43 Oil change intervals lubricants ................................................................................................... 59

Tab. 44 Regular service tasks ................................................................................................................. 59
Tab. 45 Permissible cooling oil level under LOAD .................................................................................. 67
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Tab. 46 Logged maintenance tasks ........................................................................................................ 82

Tab. 47 Spare parts ................................................................................................................................. 83

9_6917 43 USE AIRTOWER 3C–7.5C Tri-Voltage vii
List of Tables
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viii AIRTOWER 3C–7.5C Tri-Voltage 9_6917 43 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.
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➤ Enter details from the machine nameplate and individual items of equipment in the table in
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chapter 2.
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1.2 Further documents
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Further documents included with this operator manual are:
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■ 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.
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➤ Make sure you provide the data from the nameplate when ordering documents.
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1.3 Copyright
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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.
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1.4 Symbols and labels

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➤ Please note the symbols and labels used in this document.

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1.4.1 Warnings
Warning notices indicate dangers that may result in injury when disregarded.
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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 very likely result in death or severe injury
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WARNING Warns of a potentially imminent danger May result in death or severe injury
CAUTION Warns of a potentially dangerous situa‐ May result in a moderate physical injury
tion
Tab. 1 Danger levels and their definition (personal injury)
Warning notices preceding a chapter apply to the entire chapter, including all sub-sections.
Example:

9_6917 43 USE AIRTOWER 3C–7.5C Tri-Voltage 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 very likely.
➤ 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.
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Example:
1.
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The possible consequences of ignoring a warning are shown here.
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If you ignore the warning notice, the "WARNING" signal word indicates that a lethal or severe
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injury may occur.
➤ The measures required to protect yourself from danger are shown here.
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2. Always read and comply with warning instructions.
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1.4.2 Potential damage warnings
Contrary to the warnings shown above, damage warnings do not indicate a potential personal in‐
jury.
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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)

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Example:
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Potential effects when ignoring the warning are indicated here.

➤ The protective measures against the damages are shown here.
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➤ Carefully read and fully comply with warnings against damages.
1.4.3 Other alerts and their symbols

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This symbol identifies particularly important information.

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2 AIRTOWER 3C–7.5C Tri-Voltage 9_6917 43 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.
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Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
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➤ ... as is a solution.
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This symbol identifies important information or measures regarding the protection of the envi‐
ronment.
Further information
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Further subjects are introduced here.
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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 air receiver.
➤ Enter the data from the nameplate here as a reference:
Feature Value
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Rotary screw compressor
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Material No.:
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Serial No.:
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Ambient temperature
Rated power
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Max. working pressure PS
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Rated motor speed
Power Supply of Compressor
Phase:
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Frequency:
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Voltage
Full load current
Full load current drive motor
Short circuit current (rms sym.)
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Supply fuse (field provided)

Class
Power Supply of Dryer
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Phase:
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Frequency:
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Voltage
Full load current
Full load current drive motor
Short circuit current (rms sym.)
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Supply fuse (field provided)

Class
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Electrical wiring diagram
Tab. 3 Type label
2.2 Options
The table contains a list of possible options. The options for this machine are shown near the
nameplate.

2 Technical Data
2.3 Weight
➤ Enter options here as a reference:
Option Option code Available?

SIGMA CONTROL 2 C3 —
(Prepared for connection to control center)
SIGMA CONTROL 2 C48 ✓
(Connection to control technology not provided)
Bolt-down machine feet H1
Air-cooling K1 ✓
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Available: ✓
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Not available: —
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Tab. 4 Options
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2.3 Weight
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The values shown are maximum values. The actual weight of individual machines depends on
equipment fitted.
AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER

7.5C
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Weight [lb] 628 628 639 661
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Tab. 5 Weight
2.4 Temperature
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7.5C
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Minimum cut-in tempera‐ 40 40 40 40

ture [°F]
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Typical airend discharge 150 – 200 150 – 200 150 – 200 150 – 200
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temperature during oper‐

ation [°F]
Maximum airend dis‐ 230 230 230 230
charge temperature (au‐
tomatic safety shut-
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down) [°F]
Tab. 6 Temperature
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2 Technical Data
2.5 Ambient conditions
2.5 Ambient conditions

7.5C
Maximum alti‐ 3000 3000 3000 3000
tude AMSL* [ft]
Permissible ambient tem‐ 40 – 115 40 – 115 40 – 115 40 – 115
perature [°F]
Cooling air tempera‐ 40 – 115 40 – 115 40 – 115 40 – 115
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ture [°F]
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Inlet air temperature [°F] 40 – 115 40 – 115 40 – 115 40 – 115
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* Higher altitudes are permissible only after consultation with the manufacturer.
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Tab. 7 Ambient conditions
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Fig. 1 Maximum relative humidity of inlet air

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T Inlet air temperature [°F]

H Maximum relative humidity of inlet air [%]
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2.6 Ventilation
The values given are minimum guide values.

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7.5C
Inlet aperture Z see fig‐ 2.2 2.2 2.2 2.2
ure 12 [sq.ft.]
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(free area)
Extractor for forced venti‐ 883 1001 1236 1530
lation:
Flow rate [cfm] at 0.4 in.
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Tab. 8 Ventilation

2 Technical Data
2.7 Pressure
2.7 Pressure
Maximum working pressure: see nameplate
Safety relief valve activating pressure [psig]:
Max. working pres‐ AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER

sure [psig] 7.5C
125 155 155 155 155
160 230 230 230 230
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217 — 230 230 230
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Tab. 9 Safety relief valve activating pressure
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2.8 Air receiver
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Volume

7.5C
Volume [gal] 57 57 57 57
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Tab. 10 Air receiver: Volume
Safety relief valve activating pressure [psi]
Maximum working pressure: see air receiver nameplate

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sure [psi] 7.5C
155 165 165 165 165
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217 230 230 230 230

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Tab. 11 Safety relief valve: Activating pressure

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2.9 Flow rate (constant delivery volume relative to intake conditions)

Flow rate [cfm]:
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sure [psig] 7.5C
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125 12 16 21 28
160 9 13 17 24
217 — 9 13 19
Flow rate as per ISO 1217:2009 (Annex C)
Tab. 12 Flow rate [cfm]

2 Technical Data
2.10 Cooling Oil Recommendation
2.10 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.
2.10.1 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‐
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tensive internal corrosion. Water may be condensed decreasing the lubricity.
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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‐
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sorbs much of the heat of compression to cool the airend and reduce the temperature of the com‐
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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.
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2.10.2 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‐
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pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a
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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‐
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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 10.14 proper draining
procedure.
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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
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life.
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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.
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S-SERIES
■ S-Series SIGMA compressor cooling oils are synthetic lubricants.
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■ 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.

2 Technical Data
2.11 Cooling oil charge quantity
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.
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2.11 Cooling oil charge quantity
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7.5C
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Total charge [qt] 3.0 3.0 3.0 3.0
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Topping up volume [qt] 0.13 0.13 0.13 0.13
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(minimum–maximum)
Tab. 13 Cooling oil charge quantity
2.12 Motors and power

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2.12.1 Compressor motor:

7.5C
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Rated power [hp] 3 4 5 7.5

Protection rating TEFC TEFC TEFC TEFC
Tab. 14 Compressor motor

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Rated speed [rpm]:

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sure [psig] 7.5C

125 3520 3520 3520 3540
160 3520 3520 3520 3540
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217 — 3520 3520 3540
Tab. 15 Compressor motor: Rated speed

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2 Technical Data
2.13 Sound emission
2.13 Sound emission

7.5C
Sound emission [dB(A)] 69 70 70 70
Sound pressure level in operation at maximum working gauge pressure as per ISO 2151 and the
basic standard ISO 9614-2, tolerance: ±3 dB(A)
Tab. 16 Sound emission
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2.14 Power Supply
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Basic requirements
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The machine is designed for an electrical supply according to National Electric Code (NEC), edi‐
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tion 2020, particularly article 670 and NFPA 79, edition 2021, particularly section 4.4. In the ab‐
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sence 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 communication lines are to be connected to the machine, use shielded ca‐
bles and insert the same through EMC fittings into the control panel.
I
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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 the center point not solidly grounded or
three-phase (open) delta.
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The machine requires a symmetrical three-phase power supply transformer with a WYE configura‐
tion output as shown in Figure 2 and Figure 3. In a symmetrical three phase supply the phase an‐
gles and voltages are all the same.
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Other power supplies are not suitable.

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Fig. 2 Three-phase star (wye system); 4 wire; center point solidly grounded
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Fig. 3 Three-phase star (wye system); 3 wire; grounded center point solidly grounded
Further information Please contact an authorized KAESER service representative for options.
The electrical diagram 13.3 contains further specifications for electrical connection.

2 Technical Data
2.15 Power Supply specifications
2.15 Power Supply specifications

The following multi-strand copper core wires are given according to 2020 NEC 310.14, 310.15,
310.16 and table 310.16 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 2020 NEC 110.14(C), 220.3, 310.14, 310.15, 310.16, table
310.15(B)(1), table 310.15(C)(1), 430.6, 430.22, 430.24, 670.4(A) and other local codes.
Dual element time delay fuses should be selected according to 2020 NEC 240.6, 430.52 and ta‐
bles 430.52, 430.248 and 430.250.
It is recommended to use a ground conductor the same size as the current carrying conductors, if
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local codes allow. Neither the minimum ground wire size as pointed out in 2020 NEC table 250.122
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nor using conduit as the sole ground connection is recommended.
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Rated power supply 208V, 3-ph, 60Hz
o NA 7.5C
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Pre-fuse [A] 15 15 20 30
Supply per phase and AWG14 AWG14 AWG12 AWG10
ground (75 °C)
Consumption [A] 9.4 12 15 20
I
Tab. 17 Supply 208V/3/60Hz
IM

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7.5C
Pre-fuse [A] 15 15 20 25
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ground (75 °C)

Consumption [A] 8.6 11 15 19
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7.5C
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Pre-fuse [A] 10 10 10 15
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ground (75 °C)

Consumption [A] 4.3 5.5 7.6 9.4

2 Technical Data
2.16 Refrigerated dryer

Model
AIRTOWER 3C AIRTOWER 4C AIRTOWER 5C AIRTOWER 5C

Model *
*Enter the dryer model from the dryer nameplate into the table for reference.
Tab. 20 Model
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Compressed air system
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CT 4 CT 8
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Pressure drop [psi] 3 3
(referred to 100 psig
working pressure)
Maximum permissible
o NA 232 232
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working pressure [psig]
Tab. 21 Compressed air system
Refrigerant system
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The refrigerated dryer contains a refrigerant that is classified as a fluoridated global warming gas.
This refrigerant is required for the function.
The refrigerant system is hermetically sealed.
CT 4 CT 8
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Refrigerant R-513A R-513A

Global warming potential 631 631
(GWP)
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Charge quantity2) [lb] 0.37 0.55

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Charge quantity as CO2 0.1 0.2

equivalent [t]
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Maximum permitted 261 261

(high pressure end)
Maximum permitted 232 232
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(low pressure end)
Safety pressure switch: 261 261
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Cut-out pressure [psig]

2)
Volume of fluoridated global warming gases for which the refrigerant system was designed.
Tab. 22 Refrigerant system

2 Technical Data
2.16.1 Power supply specifications

The specifications given relate to the separate power supply for the integrated refrigerated
dryer. Please refer to the specifications given in chapter 6.7 and the electrical diagram in
chapter 13.3 if a common power supply is provided.
Rated power supply: 115V / 1ph / 60Hz
CT 4 CT 8
Pre-fuse [A] 15 15
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Supply per phase and AWG14 AWG14
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ground (75 °C)
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Consumption [A] 3.2 5.1
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Tab. 23 Rated power supply 115V / 1ph / 60Hz
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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.
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Disregard of warning or safety instructions can cause serious injuries!
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➤ Use this machine only if it is in a technically perfect condition and only for the purpose for
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which it is intended; observe all safety measures and the instructions in the operator manual.
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➤ Immediately rectify (have rectified) any faults that could be detrimental to safety!
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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.
I
➤ Keep to the specifications listed in this service manual.
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➤ 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
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products unless it is specifically treated.
3.3 Improper use

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Improper usage can cause damage to property and/or (severe) injuries.

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➤ Only use the machine as intended.

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➤ 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.
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➤ Do not operate the machine in areas in which specific requirements with regard to explosion
protection are in force.
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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.

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,
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■ have received adequate training and authorization to operate electrical and compressed air de‐
vices.
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■ Additional qualifications for compressors with refrigerated dryers:
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─ Adequate training and authorization on refrigeration devices.
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Authorized installation and maintenance personnel have the following qualifications:
■
o NA
are of legal age,
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■ 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,
I
■ are able to recognize the possible dangers of electrical and compressed air devices and take
IM
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,
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─ must be able to recognize the possible dangers of refrigeration devices and take appropri‐
ate measures to safeguard persons and property.
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➤ Ensure that operating, installation and maintenance personnel are qualified and authorized to
carry out their tasks.
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3.4.3 Adherence to inspection schedules and accident prevention regulations

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The machine is subject to local inspection schedules.

➤ Ensure that local inspection schedules are adhered to.
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3.5 Dangers
Basic instructions
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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.

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
The machine is designed, as standard, for separate power supplies to the compressor and
refrigerated dryer.
Touching voltage carrying components can result in electric shocks, burns or death.
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➤ All power supplies must be fitted with lockable disconnecting devices by the user.
➤ Allow only qualified and authorized electricians or trained personnel under the supervision of a
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qualified and authorized electrician to carry out work on electrical equipment according to elec‐
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trical engineering rules.
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➤ Before commissioning or recommissioning the machine, the user must ensure adequate pro‐
tection against electric shock from direct or indirect contact.
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➤ Before starting any work on electrical equipment:
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Switch off and lock out/tag 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 electrical machine heating, for exam‐
ple.
I
➤ Use fuses corresponding to machine power.
IM
➤ 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
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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.
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➤ Depressurize all pressurized components and enclosures.

➤ Do not carry out welding, heat treatment or mechanical modifications to pressurized compo‐
PR
nents (e.g. pipes and vessels) as this influences the component’s resistance to pressure.
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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‐
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clude health and life-threatening dangers.

➤ Never directly inhale compressed air.
➤ Use appropriate systems for air treatment before using the compressed air from this machine
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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 force
Springs under tension or compression are a contained force. Uncontrolled release of this energy
can cause serious injury or death.

3.5 Dangers
Minimum pressure / check valves, safety relief valves and inlet valves are powerfully spring-loaded.
➤ Do not open or dismantle any valves.
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 switched on.
➤ Switch off and lock out/tag out the power supply disconnecting device and verify the absence
of any voltage.
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➤ Wear close-fitting clothes and a hair net if necessary.
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➤ Ensure that all covers and safety guards are in place and secured before restarting.
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Temperature
High temperatures are generated during compression. Touching hot components may cause inju‐
ries.
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➤ Avoid contact with hot components.
These include, for example, compressor airends, oil and compressed air lines, coolers, oil sep‐
arator tanks, motors, and machine heaters.
➤ Wear protective clothing.
I
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
IM
heat from igniting oil vapors or parts of the machine.
Noise
The enclosure absorbs the machine noise to a tolerable level and is only effective if closed.
EL
➤ Operate the machine only with intact sound insulation.

➤ Wear hearing protection if necessary.
The safety relief valve blowing off can result in high noise emission.
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Operating fluids/materials
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The operating fluids and materials used can cause adverse health effects. Suitable safety meas‐
ec
ures must be taken in order to prevent injuries.

➤ Fire, open flame, and smoking are strictly forbidden.
➤ Follow safety regulations when dealing with oils, lubricants, and chemical substances.
➤ Avoid contact with skin and eyes.
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➤ Do not inhale oil mist or vapor.

➤ Do not eat or drink while handling cooling and lubricating fluids.
➤ Suitable fire extinguishing materials must be kept on hand.
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➤ 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 for pressure components.

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 compressed air station
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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 network or system.
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➤ When extending or modifying the compressed air system:
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Check the blow-off capacity of safety relief valves on air receivers and in compressed air lines
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before installing a new machine.
➤ If the blow-off capacity is insufficient:
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Install safety relief valves with a larger blow-off capacity.
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3.5.2 Safe machine operation
The following is information supporting you in the safe handling of the machine during individual
product life phases.
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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.
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Suitable protective clothing (examples):

■ Safety workwear
■ Protective gloves
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■ Safety boots
PR
■ Eye protection
■ Ear protection
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Transporting
The weight and size of the machine require safety measures during its transport to prevent acci‐
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dents.
➤ Use suitable lifting gear that conforms to local safety regulations.
➤ Allow transportation only by personnel trained in the safe movement of loads.
Su
➤ 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.

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.
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➤ Install the machine in a suitable compressor room.
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➤ Ensure sufficient and suitable lighting such that the display can be read and work carried out
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comfortably and safely.
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➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.
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➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
is
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‐
I
paired.
IM
➤ 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.
EL
➤ Do not position the machine in warm cooling outlet air from other machines.
➤ Keep suitable fire extinguishing agents ready for use.
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Commissioning, operation and maintenance

PR
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‐
ec
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.
bj
➤ 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.
Su
➤ 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.

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.
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De-commissioning, storage and disposal
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Improper handling of old operating fluids and components represent a danger for the environment.
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➤ Drain off fluids and dispose of them according to environmental regulations.
These include, for example, compressor oil and cooling water.
o NA
➤ Have refrigerant disposed of by authorized bodies only.
is
➤ Dispose of the machine in accordance with local environmental regulations.
3.5.3 Organizational Measures

I
➤ Designate personnel and their responsibilities.
IM
➤ 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

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The table gives information on the areas dangerous to personnel.

Only authorized personnel may enter these areas.
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Activity Danger area Authorized personnel

Transport Within a 10 ft radius of the machine. Installation personnel for transport
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preparation.
No personnel during transport.
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Beneath the lifted machine. No personnel!

Installation Within the machine. Installation personnel
Within 3 ft radius of the machine and its sup‐
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ply cables.
Operation Within a 3 ft radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
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Within a 3 ft radius of the machine.
Tab. 24 Danger Areas
3.6 Safety devices

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

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 4.9.
3.7 Working life of safety functions

The safety-relevant functions of the safety devices equipped with this machine are designed for a
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working life of 20 years. The working life starts with the commissioning, and is not extended by
times during which the machine was not in use.
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The following components are affected:
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■ Airend discharge temperature sensor (Pt100 sensor for measuring the compression discharge
temperature)
■
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EMERGENCY STOP push button
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■ Main contactor
1. The components of the safety functions 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‐
I
tions.
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3.8 Safety signs

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

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Fig. 4 Location of safety signs

3.8 Safety signs
Item Symbol Meaning

9 Personal injury or damage to the machine by incorrect operation!
➤ Read and understand the operator manual and all safety signs before switching
on this machine.
Machine starts automatically!
Severe injury could result from rotating components, electrical voltage and air pres‐
sure.
➤ Switch off and lock out the power supply disconnecting device and check that
no voltage is present before opening any machine enclosure or guard.
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10 Severe injury could result from touching the belt drive or fan blade!
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➤ Operate the machine only with fully closed safety guards, access doors and
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panels.
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➤ Isolate from the power supply and lock out before opening any machine enclo‐
sure or guard.
11
o NA
Injury and/or contamination can result from breathing compressed air!
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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 29 CFR1910.134 and
FDA 21 CFR178.3570 standards, if used for breathing or food processing. Use
I
proper compressed air treatment.
IM
13 Hot surface can cause burns!

➤ Let the machine cool down.
➤ Wear long-sleeved garments (not synthetics such as polyester) and protective
gloves.
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19 Danger of fatal injury from multiple-source electric power supplies!

➤ Before beginning any work on electrical equipment:
Switch off the main isolating devices, lock them in the off position and check
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that the machine is free of voltage.

23 Serious injury or death can result from loosening or opening component that is un‐
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der pressure and heavily spring loaded!

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➤ Do not open or dismantle the valve.

➤ Call for authorized KAESER Service representative if a fault occurs.
24 Serious injury or death can result from loosening or opening component under
pressure!
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➤ De-pressurize all pressurized components and enclosures.

➤ Secure that machine keeps de-pressurized.
➤ Check that machine is de-pressurized.
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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.

3.9 Emergency situations
Item Symbol Meaning

37 Voltage! Risk of electric shock!
Touching electrically live components can cause serious injury or death. More than
one disconnect switch may be required to de-energize the equipment before servic‐
ing.
➤ Check that no voltage is present
Tab. 25 Safety Signs
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3.9 Emergency situations
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3.9.1 Correct fire fighting
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Suitable measures
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Calm and prudent action can safe lives in the event of a fire.
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➤ Keep calm.
➤ Give the alarm.
➤ Shut off supply lines if possible.
Main disconnecting device (all poles)
Cooling water (if present)
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Heat recovery (if present)
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➤ Warn and move endangered personnel to safety.

➤ Help incapacitated persons.
➤ Close the doors.
➤ When trained accordingly: Attempt to extinguish the fire.
EL
Extinguishing substances
➤ Suitable extinguishing media:

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Foam
Carbon dioxide
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Sand or soil
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➤ Unsuitable extinguishing media:

Strong jet of water
3.9.2 Treating injuries from handling cooling oil

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Eye contact
Cooling oil can cause irritation.

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➤ 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.

3.10 Warranty
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.
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➤ Seek medical aid.
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3.9.3 Injury from Handling Refrigerant
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Eye contact:
o NA
Severe eye irritation, watering, reddening and swelling of the eyelids.
is
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.
I
Skin contact:
IM
Initially a sensation of chill, skin may redden subsequently.

Risk of frostbite.
➤ Allow the product to evaporate.
EL
➤ Rinse with lukewarm water.

➤ Consult a physician if experiencing lasting pain or reddened skin.
Inhalation:
tt
At high concentrations, risk of cardiac irregularity (arrhythmia).

PR
At very high concentration, risk of asphyxia caused by oxygen deficiency.

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➤ Remove victim to the fresh air.

➤ If necessary Respiration with respirator or administration of oxygen.
➤ Consult a physician if experiencing breathing or nerve complaints.
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3.10 Warranty
This operator manual contains no independent warranty commitment. Our general terms and con‐
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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,

3.11 Environmental protection
■ 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.
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➤ Do not allow cooling oil to escape to the environment or into the sewage system.
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➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐
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mental protection regulations.
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➤ Observe national regulations.
This applies particularly to parts contaminated with compressor cooling oil.
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4.1 Enclosure

4.1 Enclosure
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Fig. 5 Enclosure overview
1 Enclosure 4 Refrigeration dryer
2 Condensate drain viewing window 5 Bracket
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3 Air receiver
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When closed, the enclosure serves various functions:

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

■ Walking, standing, or sitting on.
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■ As a resting place or storage of any kind of load.

PR
Safe and reliable operation is only assured with the enclosure closed.
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Removing the enclosure
The enclosure 1 is removed by tipping forward (A) then lifting off (B).
bj
Replacing the enclosure
Install the enclosure in the reverse order from removal, making sure the bracket 5 engages in the
guides.
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4.2 Machine overview
4.2 Machine overview
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Fig. 6 Machine overview
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1 Inlet valve 7 Oil separator tank
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2 Minimum pressure / check valve 8 Air filter

3 Compressor drive motor 9 Oil cooler
4 Oil filter 10 Oil separator cartridge
5 Airend 11 Refrigerated dryer
6 Control cabinet 12 Air receiver
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Ambient air is cleaned as it is drawn in through the air filter 8 .

The air is then compressed in the airend 5 .
The airend is driven by an electric motor 3 .
tt
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the ro‐
PR
tors and between the rotors and the airend casing. This direct cooling in the compression chamber
ensures a very low airend discharge temperature.
ec
Cooling oil recovered from the compressed air in the oil separator tank 7 and oil separator car‐
tridge 10 gives up its heat in the oil cooler 9 . The oil then flows through the oil 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 thermostatically regulated fan keeps the cooling oil at optimum temperature.
bj
Compressed air passes through the minimum pressure / check valve 2 into the air receiver 12 .
The minimum pressure / check valve ensures sufficient internal pressure to maintain cooling oil cir‐
culation.
Compressed air is cooled in the receiver and chilled in the refrigerated dryer 11 . Most of the mois‐
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ture carried in the air is removed in this way.

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Fig. 7 Refrigerated dryer
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1 Refrigerated dryer
2 Condensate drain
3 Display: Controller power
The downstream refrigerated dryer removes moisture from the compressed air.
I
The condensate is removed via a condensate drain.
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The Controller power display is illuminated in green when the voltage supply of the refrigerated dry‐
er is activated.
4.4 Air receiver

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The compressed air stored in the air receiver smooths out peaks in air consumption. The air receiv‐
er is sized specifically for the machine and may not be used for another purpose.
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Condensate is removed automatically by the refrigerated dryer's condensate drain.

PR
This condensate drain only works when the refrigerated dryer is switched on.
➤ Condensate may be drained manually if the dryer is switched off.
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4.5 Floating relay contacts

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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.
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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.
4.6 Options
The options available for your machine are described below.

4.7 Operating modes and control modes
4.6.1 Option C3/C48

SIGMA CONTROL 2 : Connection to control technology
Connection to various control technology systems is possible with the C3 option.
Option C3 Option C48

Main Control System (MCS): Main Control System Input Output (MCSIO):
■ Slot for a communication mod‐ ■ Without slot for a communication module to connect to a
ule to connect to a control control technology system.
technology system. ■ Digital and analog inputs and outputs integrated.
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Input-Output-Module (IOM):
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■ Module with digital and analog
R R
inputs and outputs.
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Tab. 26 Components
4.6.2 Option H1 o NA
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Machine mountings
These mountings allow the machine to be anchored firmly to the floor.
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Fig. 8 Machine mountings

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4.7 Operating modes and control modes

4.7.1 Machine operating modes
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STOP
The machine is connected to the power supply.

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The voltage applied to controller LED lights green.

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

■ The ON LED lights green.
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■ The drive motor is stopped.

■ The inlet valve is closed.
■ The minimum pressure/check valve isolates the oil separator tank from the air system.
■ The venting valve is open.
The compressor motor starts as soon as pressure is demanded.

4.8 Refrigerated dryer control modes
LOAD
The compressor motor runs under load.

■ The inlet valve is open.
■ The airend delivers compressed air to the system.
4.7.2 START-STOP control

Using the selected control mode, the controller toggles the machine between the operating modes
LOAD and READY in order to compensate for air being drawn by consumers and to maintain the
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system pressure between the set minimum and maximum values.
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The machine automatically continues to run under LOAD if the duty cycle is too low. This
event lasts a few minutes, at maximum.
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A sufficient duty cycle prevents harmful condensate.
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4.8
o NA
Refrigerated dryer control modes
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The controller can work in the following control modes:
■ CONTINUOUS
CONTINUOUS
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In this mode the refrigerated dryer runs continuously, even if the compressor is not running.
The refrigerated dryer is switched off together with the compressor.
4.9 Safety devices

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The following safety devices are provided and must not be modified or disabled.
■ EMERGENCY STOP push button:
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The EMERGENCY STOP push button shuts down the compressor immediately. The motor is
stopped. The pressure system is vented.
PR
■ Safety relief valve:

The safety relief valve protects the system against excessive pressure. It is factory set.
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■ Airend discharge temperature sensor:

Monitoring the airend discharge temperature protects the compressed air system from imper‐
missible temperature rises.
■ Safety pressure monitor:
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The safety pressure monitor protects the refrigerant circuit of the refrigerated dryer against ex‐
cessive pressure. It cannot be set.
■ Enclosure and covers for moving parts and electrical connections:
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Protect against accidental contact.

4.10 Operating panel SIGMA CONTROL 2

Keys
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Fig. 9 Keys – overview
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Position Name Function

1 «OFF» Switches the machine off.
2 «ON» Switches the machine on.
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3 «Escape» Returns to the next higher menu option level.

Exits the edit mode without saving.
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4 «Enter» Jumps to the selected submenu option.

Exits the edit mode and saves.
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5 «Down» Scrolls down the menu options.

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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.
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Moves the cursor position to the next left field.

8 «Up» Scrolls up the menu options.
Increases a parameter value.
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9 «Events and Information» Operating mode:

Displays the event memory.
10 «Acknowledgement» Confirms/acknowledges alarms and warning messages.
If permissible: Resets the fault counter (RESET).
11 «LOAD/IDLE» Key without function.
12 «Remote control» Switches the remote control on and off.


13 «Timer control» Switches the timer control on and off.
Tab. 27 Keys
Indicators
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Fig. 10 Indicators overview

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14 Indicator field or Graphic display with 8 lines and 30 characters per line.
Display
15 Alarm Flashes red to indicate a machine alarm.
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Continuous red light after acknowledgement.

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16 Communications error Continuous red light to indicate a defective communication con‐

nection, or an external alarm message without machine shut‐
ec
down.
17 Warning Flashes in yellow in the following events:
■ Maintenance necessary
■ Warning message
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Continuous yellow light after acknowledgement.

18 Voltage applied to Continuous green light when voltage is applied to the controller.
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controller
19 LOAD Continuous green light when the machine is running in LOAD.
20 IDLE Display without function.
21 Remote control Continuous green light when the machine is in remote control.
22 Timer control Continuous green light when the machine is controlled by the
timer.


23 ON Continuous green light when the machine switched on.
Tab. 28 Indicators
RFID reader
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 KAESER RFID reader of the controller will automati‐
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cally activate the communication between transponder and SIGMA CONTROL 2.
A suitable transponder is the KAESER RFID Equipment Card. Two of them have been provided
n
with the machine.
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Typical application:
■ Users log on at the machine.
o NA
(Manual input of the password not required.)
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Fig. 11 RFID reader

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Item Description Function

24 KAESER RFID RFID reader for the communication with a suitable RFID Equipment Card or
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RFID Key.
PR
Tab. 29 RFID reader

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Further information More information about the use of KAESER RFID technology is provided in the
SIGMA CONTROL 2 operating manual.
bj
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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!
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Complying with safety warnings
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Disregard of safety warnings can cause unforeseeable dangers!
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➤ Strictly forbid fire, open flame and smoking.
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➤ 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.
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➤ Do not store inflammable material in the vicinity of the machine.
is
➤ 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.
I
➤ Keep suitable fire extinguishing agents ready for use.
IM
➤ Ensure that required ambient conditions are maintained.
Required ambient conditions may be:

■ Maintain ambient temperature and humidity
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■ 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.
tt
─ Free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen sul‐

fide.
PR
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5.2 Installation conditions

5.2.1 Determining location and clearances
bj
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‐
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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.

5.2 Installation conditions
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Fig. 12
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Recommended machine placement and dimensions [in]
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A Exhaust fan
Z Ventilation inlet air opening
1. Ambient temperature too low!

Frozen condensate and highly viscous cooling oil can cause damage when starting the ma‐
I
chine.
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➤ 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.
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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 air inlet and exhaust air openings of the enclosure remain opened.
5. If installed outdoors, the machine must be protected from frost, direct sunlight, dust, and rain.
tt
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5.2.2 Ensuring adequate ventilation

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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.
bj
➤ Consult with KAESER if you cannot ensure the conditions for adequate ventilation of the
machine room.
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1. Ensure that the flow rate of fresh air is at least the same as the flow rate taken by the machine
and exhaust fan from the machine room.
2. Make sure that the machine and exhaust fan can only operate when the ventilation inlet air
opening is actually open.
3. Keep the inlet and exhaust openings 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.

5.3 Operating the machine in a compressed air system
5.3 Operating the machine in a compressed air system

When the machine is connected to a compressed air system, the system operating pressure must
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 system, we recommend the installation of
an air main charging system.
➤ Consult an authorized KAESER service representative for advice on this subject.
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6 Installation
6.1 Ensuring safety
6 Installation
6.1 Ensuring safety
Follow the instructions below for safe installation.
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Disregard of safety warnings can cause unforeseeable dangers.
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➤ Follow the instructions in chapter 3 "Safety and Responsibility".
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➤ Installation work may only be carried out by authorized personnel.
➤ Make sure that no one is working on the machine.
o NA
➤ Ensure that all service doors and panels are locked.
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When working on live components
➤ Work on electrical equipment may only be carried out by authorized electricians.
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of any voltage.
➤ Check that the floating relay contacts are voltage-free.
When working on the compressed air system

EL
or death. The following safety concerns relate to any work on components that could be under
pressure.
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➤ Fully vent all pressurized components and enclosures.

ec
➤ Check all hose couplings in the compressed air system with a handheld pressure gauge to en‐
sure that they all read 0 psig.
bj
When working on the drive system
Touching the fan wheel or belt drive while the machine is running can result in serious injury.
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of any voltage.
Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance can be found in chapter 3.5.

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 to the compressed air network

Condensate in the compressed air network can damage the pipework:
➤ Install only corrosion-resistant pipes.
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➤ Use fluoroelastomers as sealing material for seals.
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➤ Note the electrochemical voltage sequence.
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➤ Contact an authorized KAESER service representative concerning suitable materials for
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the compressed air network.
Precondition The compressed air system is vented completely to atmospheric pressure.
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Fig. 13 Compressed pipework

1 Flexible pressure hose
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2 Shut-off valve
1. Serious injury or death can result from loosening or opening components under
pressure!
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2. Connect a flexible pressure hose.

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Further information The dimensional drawing in chapter 13.2 provides the size and position of the connection ports.
6.4 Connecting the condensate drain

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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
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to the condensate collecting line.

Fig. 14 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.

6 Installation
6.4 Connecting the condensate drain
Condensate line
Feature Value
Max. length [ft]
1) 50
Max. delivery head [ft] 16
Material Copper
(pressure-resistant, cor‐ Stainless steel
rosion-proof)
Plastics
Hose line
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1)
For longer lengths, please contact KAESER before installation.
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Tab. 30 Condensate line
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Condensate collecting line
Feature
o NA Value
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Gradient [%] ≥3
Max. length [ft]
1) 65
Material Copper
(pressure-resistant, cor‐ Stainless steel
I
rosion-proof)
Plastics
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Hose line
1)
For longer lengths, please contact KAESER before installation.
Tab. 31 Condensate collecting line

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Compressed air flow Line diameter ["]

rate1) [cfm]
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<350 3/4
350 – 730 1
PR
731 – 1410 1 1/2

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>1410 2
1)
Compressed air flow rate as guide for the condensate volume to be expected
Tab. 32 Condensate collecting line: Line diameter

bj
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6 Installation
6.5 Connecting the external pressure transducer
Connecting the condensate drain
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Fig. 14
o NA
Connecting the condensate drain
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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
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Depending on the machine model, you may have several condensate drains.
IM
➤ 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 13.2 provides the size and position of the connection port.
EL
6.5 Connecting the external pressure transducer

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Material Retrofit kit: "External pressure transducer SIGMA CONTROL 2"

PR
Use suitable shielded, copper-core cable (e.g.: LIYCY 2 x0.75 mm2 for ambient temperature up to
30°C and laying method C).
ec
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.
bj
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.
Su
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.

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 13.3 contains further details of the pressure transducer connec‐
tion.
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6.6 Option T2
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Refrigerated dryer: Connecting the transformer according to the
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power supply.
o NA
The refrigerated dryer transformer has tappings for various power supply voltages.
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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 13.3 contains further details of the power supply connection.
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6.7 Making the Power Supply Connection

The machine is designed for separate power supplies to the compressor and refrigerated dryer. A
main power supply for the dryer is required in addition to one for the compressor.
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The nameplate gives the specification of the power supply.
This is a Tri-Voltage machine. The machine can be set up to one of the following supply voltages:
■ 208V
tt
■ 230V
PR
■ 460V
ec
1. Have the power supply connected only by authorized installation personnel or an authorized
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.
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6.7.1 Changing main voltage connections

Machine set up for [V] 208 230 460
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Machine may be modified 230 208 208

[V] 460 460 230
Tab. 33 Voltage selection
The following parts have to be considered for making the change:

■ Motor connection terminals in the control cabinet.

6 Installation
6.7 Making the Power Supply Connection
■ Drive motor overload protection relay

■ Control transformer
Material The required jumpers (also known as ’bridges’ or ’links’) are provided in the control cabinet.
Precondition A check has been made to ensure no voltage is present.
Changing the drive motor connection
➤ Open the control cabinet and connect the motor in accordance with the electrical diagram.
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Adjusting the overload protection cutout
n
➤ Check the overload protection relay setting.
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7.5C
208V, 3-ph, 60Hz [A]
o NA 5.7 7.1 9.5 12.2
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230V, 3-ph, 60Hz [A] 5.3 6.7 9.5 11.7
460V, 3-ph, 60Hz [A] 2.6 3.4 4.7 5.9
Tab. 34 Overload protection cutout settings.

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Connecting the control transformer (–T1)
➤ Open the control cabinet and connect the control transformer in accordance with the electrical
diagram.
6.7.2 Connect power to the machine

EL
Each power supply must have its own isolating device. Both isolating devices must be switch‐
ed off before working on the electrical equipment. This is possible by a mechanical locking
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mechanism, for example.

PR
Danger of fatal injury from a dual electric power supply.

ec
➤ Ensure that both power supplies are always switched off together.
1. Test the overcurrent protection cut-out to ensure that the time it takes to disconnect in re‐
sponse to a fault is within the permitted limit.
bj
2. Select supply cable conductor cross-sections and fuses in accordance with local regulations.
3. All power supplies must be fitted with lockable isolating devices by the user.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is
Su
used it must be suitable for the motor starting characteristics.

4. 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.
5. Connect the power supply in accordance with the electrical diagram in chapter 13.3.

6 Installation
6.8 Options
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 13.2.
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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.
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Ignoring safety warnings can cause unforeseeable dangers.
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➤ Follow the instructions in chapter 3 "Safety and Responsibility".
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➤ Commissioning tasks may only be carried out by authorized personnel!
➤ Make sure that no one is working on the machine.
o NA
➤ Ensure that all service doors and panels are locked.
is
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of any voltage.
➤ Check that the floating relay contacts are voltage-free.

EL
pressure.
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PR

ec
➤ Check all hose couplings in the compressed air system with a handheld pressure gauge to en‐
bj
Touching the fan wheel or belt drive while the machine is running can result in serious injury.
Su
of any voltage.
Further information Details of authorized personnel can be found in chapter 3.4.2.

Details of dangers and their avoidance can be found in chapter 3.5.

7 Initial Start-up
7.2 Instructions to be observed before commissioning
7.2 Instructions to be observed before commissioning

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

standstill period
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longer than
n
3 months ➤ Manually fill the airend with cooling oil.
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12 months ➤ Change the oil filter.
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➤ Change the oil separator cartridge.
➤ Change the cooling oil.
o NA
➤ Manually fill the airend with cooling oil.
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36 months ➤ Have the overall technical condition checked by an authorized KAESER
service representative.
Tab. 35 Re-commissioning after storage/standstill

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7.3 Checking installation and operating conditions

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

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chapter
➤ Are the operators fully familiar with safety regulations? –
➤ Have all the installation conditions been fulfilled? 5
tt
➤ Is a user-supplied lockable power supply disconnecting device instal‐ 6.7

led?
PR
➤ Are the tolerance limits of the power supply within the permissible tol‐ 13.3
ec
erance limits of the rated machine voltage?

(See nameplate in the control cabinet)
➤ Are the power supply cable conductor cross-sections and fuse rat‐ 2.15
ings adequate?
bj
➤ Is the drive motor overload protection switch set according to the 7.4
power supply voltage?
➤ Have all electrical connections been checked for tightness? –
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➤ Has the inspection been repeated after 50 operating hours following

the initial commissioning?
➤ Has the connection to the air system been made with a shut-off valve 6.3
and a flexible hose?
➤ Is the condensate drain connected? 6.4
➤ Is there sufficient cooling oil in the airend? 7.5
➤ Is the machine firmly anchored to the floor? 6.8.1
(Option H1)

7 Initial Start-up
7.4 Setting the overload protection relay
To be checked See Confirmed?

chapter
➤ Is the belt guard and enclosure cover closed? –
Tab. 36 Installation conditions checklist
7.4 Setting the overload protection relay

Electrical diagram 13.3 gives the location of the overload protection relay.
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With star-delta starting, the phase current is fed via the overload protection relay. This phase cur‐
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rent is 0.58-times the rated motor current.
To prevent the overload protection relay from being triggered by voltage fluctuations, temperature
R R
influences or component tolerances, the setting can be higher than the arithmetical phase current.
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➤ Check the overload protection relay setting.
o NA
The overload protection relay shuts the machine down despite being correctly set?
is
➤ Contact an authorized KAESER service representative.
7.5 Pouring cooling oil into the airend

I
Before starting the compressor for the very first time and before re-starting after a shutdown period
IM
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 10.14 provides detailed information on how to drain cooling oil from the oil separator tank.
EL
Material 0.26qt. cooling oil
Precondition The supply disconnecting device is switched off,

the device is locked off,
tt
the absence of voltage has been verified.

PR
ec
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Fig. 15 Inlet valve filling port

1 Filler plug
2 Airend
1. Unscrew and remove the filler plug.

2. Pour in the cooling oil and retighten the filler plug.
3. Turn the airend manually by means of the belt pulley to distribute the cooling oil.

7 Initial Start-up
7.6 Starting the machine for the first time
7.6 Starting the machine for the first time

Precondition No personnel are working on the machine.
All access doors are closed.
All removable panels in place and secured.
1. Open the user's 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 voltage LED is lit continu‐
ously.
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3. If required:
n
Change the display language as described in chapter 7.8.
4. Press the «ON» key.
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The drive motor runs up and after a short time the machine switches to LOAD and delivers
compressed air.
o NA
➤ Watch for any faults occurring in the first hour of operation.
is
➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.
Does the machine stop because the compressor motor is rotating in the wrong direction?
➤ Switch off and lock out/tag out the power supply disconnecting device and verify the ab‐
sence of any voltage.
I
➤ Changeover phase lines L1 and L2.
IM
➤ Acknowledge any existing alarm messages and switch the machine on again.
7.7 Setting the set point pressure

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The system pressure pA is factory set to the highest possible value.

Adjustment is necessary for individual operating conditions.
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Do not set the set point pressure of the machine higher than the maximum working pressure
of the compressed air system.
PR
The machine may not toggle more than twice per minute between LOAD and IDLE.
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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 set point pressure as described in the SIGMA CONTROL 2 operating manual.
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7.8 Setting the display language

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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.

7 Initial Start-up
7.8 Setting the display language
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
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3. Use the «Return» key to switch to setting mode.
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The language display flashes.
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4. Move to the required language with «UP »or «DOWN».
5. Confirm the setting with the «Enter» key.
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Result The display texts are now in the selected language.
Further information Detailed information can be found in the SIGMA CONTROL 2 operating manual.
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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 has been installed by the user.
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Fig. 16 Switching on and off
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1 ON LED 3 «OFF» key

2 «ON» key 8 Voltage applied to controller LED
8.1.1 Switching on
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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.

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The Voltage applied to controller LED is lit continuously.

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2. Press the «ON» key.

The green ON LED lights continuously.
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If a power failure occurs, the machine is not prevented from automatic restarting.
It can start automatically again as soon as power is restored.
Result The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut-
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off pressure).
8.1.2 Switching off

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1. Press the «OFF» key.

The machine is in ready to operate as soon as the ON LED is extinguished. The machine can
be started again.
2. Switch off and lock out/tag out all power supply disconnecting devices.
Result 7 The Voltage applied to controller LED and the Controller voltage LED (see fig. 7) are extinguish‐
ed. The machine is switched off and disconnected from the power supply.

8 Operation
8.2 Switching off in an emergency and switching on again
8.2 Switching off in an emergency and switching on again

The EMERGENCY STOP push button is located below the control panel.
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Fig. 17 Switching off in an emergency
9 EMERGENCY STOP push button
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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-
I
starting.
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Switching on
Precondition The fault has been rectified

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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.

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8.3 Switching on and off from a remote control center

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Precondition A link to the remote control center exists.

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Fig. 18 Switching on and off from a remote control center

1 «Remote control» key
2 Remote control LED

8 Operation
8.4 Using the timer for switching on and off
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. 37 Machine identification
2. Label the starting device in the remote control center as follows:
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Remote control: Risk of injury caused by unexpected starting!
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➤ Before starting, make sure that no one is working on the machine and that it can be safely
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started.
Tab. 38 Remote control center identification
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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

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Precondition The clock is programmed.

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Fig. 19 Using the timer for switching on and off

1 «Timer» key
2 Timer LED
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1. Attach an easily seen notice to the machine that warns of time-controlled operation:
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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. 39 Warning notice for timer control
2. Press the «Timer» key.

The Timer LED lights. The timer switches the machine on and off.

8 Operation
8.5 Interpreting operation messages
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
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Messages are displayed on the "new value" principle:
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■ Message coming: LED flashes
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■ Message acknowledged: LED illuminates
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■ Message going: LED off
or
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■ Message coming: LED flashes
■ Message going: LED flashes
■ Message acknowledged: LED off
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Fig. 20 Acknowledging messages

10 LED Warning (yellow)
11 LED Alarm (red)
12 Key «Acknowledge»
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Alarm message
An alarm shuts the machine down automatically. The red alarm LED flashes.
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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.

8 Operation
8.6 Acknowledging alarm and warning messages
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.
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The system displays the appropriate message.
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Precondition The danger of an alarm is passed,
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maintenance has been carried out.
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➤ Acknowledge the message with the «Acknowledge» key.
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The warning LED extinguishes.
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Further information A list of possible alarm messages occurring during operation can be found in the service manual
SIGMA CONTROL 2 .
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There are 3 types of fault:
■ Warning:
─ Warning messagesW
■ Fault (with indication):
─ Alarm messagesA
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─ System messages Y
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─ Diagnostic messages D
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■ Other faults (without indication): See chapter 9.2
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The messages valid for your machine are dependent on how the individual machine is equipped.
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1. Do not attempt fault rectification measures other than those given in this manual!
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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.
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9.2 Other Faults

Fault Possible cause Remedy
Machine does not run. Control transformer not wired. Connect control transformer in
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accordance with the electrical

diagram.
Machine with refrigeration dry‐
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er:
Connect dryer transformer in
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accordance with the electrical

diagram.
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Machine runs but produces no Inlet valve not opening or only Call authorized KAESER Serv‐
compressed air. opening partially. ice representative.
Venting valve not closing. Call authorized KAESER Serv‐
ice representative.
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Leaks in the pressure system. Check piping and connections

for leaks and tighten any loose
fittings.
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Air consumption is greater than Check the air system for leaks.
the capacity of the compressor. Shut down the 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.

9.2 Other Faults
Fault Possible cause Remedy

Cooling oil runs out of the air fil‐ Oil level in the oil separator Drain off oil until the correct lev‐
ter. tank too high. el is reached.
Inlet valve defective. Call authorized KAESER Serv‐
ice representative.
Compressor switches between Air receiver too small. Increase size of air receiver.
LOAD and IDLE more than Airflow into the compressed air Increase air pipe diameters.
twice per minute. network restricted. Check filter elements.
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The differential between cut-in Check switching differential.
and cut-out pressure too is
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small.
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Cooling oil leaking into the floor Hose coupling or maintenance Remove coupling or mainte‐
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pan. hose still plugged into the nance hose.
quick-release coupling on the
o NA oil separator tank.
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Oil cooler leaking. Call authorized KAESER Serv‐
ice representative.
Leaking joints. Tighten joints.
Replace seals.
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Cooling oil consumption too Unsuitable oil is being used. Use SIGMA FLUID cooling oil.
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high. 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.
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Oil return line clogged. Check dirt trap in the return

line.
Tab. 40 Other faults and actions

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10 Maintenance
10.1 Ensuring safety
10 Maintenance
10.1 Ensuring safety
Follow the instructions below to ensure safe machine maintenance.
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Complying with safety notes
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Disregard of safety notes can cause unforeseeable dangers!
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➤ Follow the instructions in chapter 3 “Safety and Responsibility”.
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➤ 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:
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Sign Meaning
Serious injury or death can result from activating the machine during service!
➤ Do not activate the machine.
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Tab. 41 Warn others that the machine is being serviced.
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➤ Before switching on, make sure that nobody is working on the machine and all access doors
and panels are closed and locked.

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Touching voltage-carrying components can result in electric shocks, burns, or death.

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➤ Switch off and lock out the power supply disconnecting device and verify the absence of volt‐
age.
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➤ Check that there is no voltage on floating relay contacts.

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pressure.
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➤ Depressurize all pressurized components and enclosures.

➤ Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
Touching voltage-carrying components can result in electric shocks, burns, or death.

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.
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.
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10.2.1 Logging maintenance work
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The maintenance intervals given are those recommended for KAESER original components
with average operating conditions.
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➤ In adverse conditions, perform maintenance work at shorter intervals.
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Adverse conditions are, e.g.:
■ high temperatures
■ much dust
■ high number of load changes
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■ low load
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➤ Adjust the maintenance intervals with regard to local installation and operating condi‐
tions.
➤ Document all maintenance and service work.
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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 10.19.

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10.2.2 Resetting maintenance interval counters

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

The table below lists the required maintenance tasks.
The refrigeration circuit is hermetically sealed. Repairs may only be carried out by certified person‐
nel.

10 Maintenance
➤ Take note of the controller's service messages and carry out tasks in a timely manner, taking
ambient and operating conditions into account:
Interval Maintenance task See chapter

Weekly Check the cooling oil level. 10.11
Cooler: 10.3
Check the filter mat.
Check the condensate drain. 10.17.2
Air receiver: 10.18
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Drain condensate manually.
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Up to 1000 h Clean the cooler. 10.4
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Check the air filter. 10.5
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Cooler: 10.3
Clean the filter mat.
o NA Clean the refrigerant condenser. 10.17.1
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Up to 3000 h Cooler: 10.3
Change the filter mat.
Up to 6000 h Condensate drain: 10.17.2.2
At least every 2 years Change the service unit.
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Display: Maintain the drive belt. 10.7
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SIGMA CONTROL 2 Change the air filter. 10.5

Display: Change the oil filter. 10.15
SIGMA CONTROL 2
At least every 2 years
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Display: Change the oil separator cartridge. 10.16

SIGMA CONTROL 2
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Varies, see table 43 Change the cooling oil. 10.14

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Up to 6000 h Replace the drive belt. 10.7

At least every 1 years Machine: 10.8
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Check the safety relief valve.

Check the function: 10.9
Safety shutdown due to excessive airend discharge tem‐
perature.
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Check the EMERGENCY STOP push button. 10.10

Have the pressure monitor checked by an authorized —
KAESER service representative.
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Check the cooler for leaks. 10.4

Check that all electrical connections are tight. —
h = operating hours
Tab. 42 Regular maintenance tasks

10 Maintenance
10.3 Clean or replace the filter mat
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.
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KAESER LUBRICANTS
SIGMA Lubricant Description Maximum Recommended Change Interval
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First oil change Subsequent oil change
M-460 ISO 46 Semi-Synthetic 2000 Hours 3000 Hours
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S-460 ISO 46 Synthetic Lu‐ 6000 Hours 8000 Hours
bricant
S-680 ISO 68 Synthetic Lu‐ 6000 Hours 8000 Hours
bricant
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FG-460 ISO 46 Food Grade 2000 Hours 3000 Hours
Synthetic Fluid
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Tab. 43 Oil change intervals lubricants
10.2.5 Regular service tasks

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The table below lists necessary service tasks.

➤ Have an authorized KAESER service representative carry out service tasks.
➤ Have service tasks carried out in a timely manner, taking the ambient and operating conditions
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into account:
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Interval Service task

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Display: Service valves.

SIGMA CONTROL 2 Compressor drive motor:
Replace the anti-friction bearing.
Up to 36000 h Have the plastic pipes and hose lines replaced.
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At least after 20 years Replace safety-relevant components of the safety functions.
h = operating hours
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Tab. 44 Regular service tasks
10.3 Clean or replace the filter mat

The filter mats help to keep the cooler clean. If the filter mat is clogged, adequate cooling of the
components is no longer guaranteed.

10 Maintenance
10.4 Cooler maintenance
Material Filter mats:

Warm water with household detergent.
Spare parts (as required).
Precondition The machine is switched off.
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Fig. 21 Filter mat
1 Filter mat
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No tools are needed to remove the filter mat.
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1. Carefully remove the filter mat from the retaining frame.

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 is up.
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4. Carefully insert the filter mat in the retaining frame.
10.4 Cooler maintenance

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Regular cleaning of the cooler ensures the reliable cooling of the machine and the compressed air.
Frequency of maintenance is mainly dependent on local operating conditions.
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A leaking cooler results in loss of cooling oil and pressure.
Material Brush and vacuum cleaner

Face mask (as required)
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lock out and tag out the device,
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The machine has cooled down.

10 Maintenance
10.5 Change the air filter
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Fig. 22 Oil cooler
1 Oil cooler
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Cleaning the cooler
Do not use sharp objects to clean the cooler. It could cause damage.
Avoid creating clouds of dust.
➤ Dry brush the oil cooler and use a vacuum cleaner to suck up the dirt.
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The oil cooler can't be cleaned thoroughly?

➤ Have severe clogging removed by an authorized KAESER service representative.
Checking the cooler for leaks

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➤ Carry out visual inspection: Can oil be seen escaping?

Is the cooler leaking?
➤ Have the defective cooler repaired immediately by an authorized KAESER service repre‐
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sentative.
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10.5 Change the air filter

All sealing surfaces have been designed to match each other. The use of an unsuitable air
filter can permit dirt to enter the pressure system, thus causing damage to the machine.
The air filter cannot be cleaned.
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Material Spare part

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10 Maintenance
10.6 Compressor motor maintenance
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Fig. 23 Change the air filter
1 Fastener
2 Air filter
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3 Air filter housing
1. Release the fasteners at the air filter housing and remove the air filter.
2. Clean all parts and sealing surfaces.
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3. Insert the new air filter into the housing.
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4. Close the air filter housing with the fasteners.
10.6 Compressor motor maintenance

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The motor bearings of the compressor motor are permanently greased. Re-greasing is not neces‐
sary.
➤ Have the motor bearings checked by an authorized KAESER service representative during the
course of a visit.
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10.7 Changing the drive belt

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Material Spare part (if required)

lock out / tag out the device,
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the absence of all voltage is verified.

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➤ Switch off and lock out / tag out the power supply disconnecting device, verify the ab‐
sence of all voltage.

10 Maintenance
10.8 Checking the safety relief valve activating pressure
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Fig. 24 Drive belt maintenance
1 Fixing screw 5 Tensioning device
2
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Pivot point fixing screw 6 Belt guard
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3 Tensioning nut 7 Turn lock
4 Markings 8 Belt pulley
Changing the drive belt

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In order to be able to change the drive belt, the compressor motor must be moved in its bracket.
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Use the appropriate tool and secure the compressor motor while fitting the new drive belt.
1. Open turn locks 7 and remove the belt guard 6 .
2. Loosen the tensioning nut 3 by approx. 0.4 inches.
3. Undo all fixing screws 1 .
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4. Move the compressor motor aside and secure it in position with one of the screws 1 .
5. Place the new drive belt over the belt pulley.
6. Tension the belt with the tensioning nut 3 until both markings 4 coincide.
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7. Ensure that all screws 1 are loosened.

8. Tighten one of the fixings screw 1 to fix the compressor motor in place, then tighten the rest 1
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and 2 .
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9. Replace the belt guard and close the turn locks.
Result The drive belt is sufficiently tensioned.

It is not necessary to readjust the belt tension.
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In order to check the safety relief valve's activating pressure, the machine's working pressure is
raised above the activating pressure of the valve.
Material Service fittings with accessories

(fixed to the machine)
Precondition The machine is shut down.

The user's shut-off valve between the machine and the compressed air network is closed.

10 Maintenance
1. Note the safety relief valve activating pressure.

(The activating pressure is usually to be found at the end of the part identification)
2. Checking the compressor safety relief valve
3. Checking the air receiver safety relief valve
10.8.1 Checking the compressor safety relief valve

Precondition The machine is completely vented to atmospheric pressure,
i.e. both pressure gauges 2 and 9 (see Fig 29) are showing 0 psig.
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Fig. 25 Compressor: Checking the safety relief valve

1 Air pipe 4 Service fittings
2 Clamping nut 5 Clamping nut
Air pipe connection
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1. Undo the union nut 2 and remove the air pipe 1 .

2. Seal the connection for the air pipe 3 with service fitting 4 and union nut 5 .
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3. Carry out an inspection as described in section 10.8.3.

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4. Switch the machine off and depressurize completely.

Both pressure gauges 2 and 9 (Fig. 29) read 0 psig.
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5. Remove the fitting 4 and replace the air pipe 1 .
10.8.2 Checking the air receiver safety relief valve

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Precondition The machine is completely vented to atmospheric pressure,

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10 Maintenance
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Fig. 26 Air receiver: Check the safety relief valve
1 Safety relief valve
2
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Copper gasket
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4 Service fitting
1. Loosen the safety relief valve 1 and remove together with the copper gasket 2 .
2. Fit the service fitting 4 with copper gasket 2 in place of the safety relief valve.
3. Carry out an inspection as described in section 10.8.3.
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4. Switch the machine off and depressurize completely.
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Both pressure gauges 2 and 9 (Fig. 29) read 0 psig.

5. Remove the service fitting 4 and replace it with the safety relief valve and a new copper gas‐
ket.
6. Open the user's shut-off valve between the machine and the compressed air network.
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10.8.3 Performing the test

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The machine starts and runs under LOAD as long as the «ON» button is held down. Pressure in
the receiver to be checked rises. The time taken until the safety relief valve blows off depends on
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the volume of the air receiver. The machine switches to READY as soon as the «ON» button is
released.
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➤ Follow the detailed description of this procedure in the SIGMA CONTROL 2 operating
manual
➤ Never operate the machine without a correctly functioning safety relief valve.
➤ Have a defective safety relief valve replaced immediately.
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Precondition The machine is switched off.
1. The safety relief valve blows off!

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Excessive noise is caused when the safety relief valve blows off.
There is danger of scalding from hot oil.
There is danger of injury from bursting components and compressed air.
➤ Close the enclosure.
➤ Wear ear and eye protection.
➤ Abort the test if the working pressure rises 10 % above the activating pressure of the valve.
2. Log on to SIGMA CONTROL 2 with password access level 2.
3. Observe the display of pressure on SIGMA CONTROL 2 and call up the test function.

10 Maintenance
10.9 Checking the overheating safety shutdown function
4. 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.
5. End the test as soon as the safety relief valve blows off or working pressure exceeds the ac‐
tuating pressure of the safety relief valve by nearly 14.5 psig.
6. If necessary, vent the machine and replace the defective safety relief valve.
7. Deactivate the test function.
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10.9 Checking the overheating safety shutdown function
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The machine should shut down if the airend discharge temperature reaches a maximum of 230 °F.
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➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐
ual.
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The machine does not shut down?
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➤ Have the safety shutdown function checked by an authorized KAESER SERVICE repre‐
sentative.
10.10 Testing the EMERGENCY STOP push button

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Fig. 27 Testing the EMERGENCY STOP push button

9 EMERGENCY STOP push button
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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
bj
from automatically restarting.

The compressor motor does not stop?
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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 Maintenance
10.11 Checking the cooling oil level
10.11 Checking the cooling oil level

The sight glass allows a risk-free reading of the cooling oil level. The oil indicator should be fully
filled with oil when the machine is at standstill. The correct oil level cannot be seen.
The ideal situation is with the oil level around the optimum mark when the machine is running.
Operating state Minimum oil level Maximum oil level
LOAD
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Tab. 45 Permissible cooling oil level under LOAD
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Precondition The machine has been running at least 5 minutes under LOAD.
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Fig. 28 Checking the cooling oil level

1 Minimum oil level
2 Maximum oil level
3 Optimum oil level
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➤ Check the cooling oil level with machine running under LOAD.
Result As soon as the minimum level is reached: Replenish the cooling oil.
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10.12 Venting the machine (depressurizing)

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Venting takes place in three stages:

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

verify the absence of any voltage.

10 Maintenance
10.12 Venting the machine (depressurizing)
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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Fig. 29 Venting the machine
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1 Hose coupling (air receiver venting) A Shut-off valve open

2 Pressure gauge B Shut-off valve closed
3 Hose coupling (oil separator tank venting) 8 Maintenance hose
6 Male plug in hose fitting 9 Pressure gauge
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7 Shut-off valve
Isolating the machine from the air system

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

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➤ 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 user's shut-off valve is closed or that the complete air system is ven‐
Su
ted.
➤ With the shut-off valve closed, insert the male plug in hose fitting 6 into the hose cou‐
pling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male plug in 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.

10 Maintenance
10.13 Replenishing cooling oil
Manually vent the air receiver
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. The air cooler pressure gauge 9 shows this pressure.
1. With the shut-off valve closed, insert the male plug in hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
The pressure gauge 9 on the air receiver indicates 0 psig.
3. Disconnect the male plug in hose fitting 6 and close the shut-off valve 7 .
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The air receiver pressure gauge does not read 0 psig after venting?
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Result The machine is fully depressurized when both pressure gauges 2 and 9 show 0 psig after manual
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venting.
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Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
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the oil separator tank.

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Fig. 30 Replenishing cooling oil

1 Hose coupling (air receiver 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
4 Oil filler port with plug 8 Maintenance hose
5 Cooling oil level indicator 9 Pressure gauge
6 Male plug in hose fitting

10 Maintenance
1. Vent the machine as described in section 10.13.1.

2. Fill with cooling oil and test run as described in section 10.13.2.
10.13.1 Venting the machine (depressurizing)

Venting takes place in three stages:
■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air receiver.
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Escaping oil mist is damaging to health.
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➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.
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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.
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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 2 reads 0 psig.
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The pressure gauge does not read 0 psig after automatic venting?
➤ Make sure that the user's shut-off valve is closed or that the complete air system is ven‐
ted.
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➤ With the shut-off valve closed, insert the male plug in hose fitting 6 into the hose cou‐
pling 3 .
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➤ Slowly open the shut-off valve 7 to release pressure.

➤ Disconnect the male plug in hose fitting 6 and close the shut-off valve 7 .
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➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact
an authorized KAESER service representative.
Manually vent the air receiver

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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. The air receiver pressure gauge 9 shows this pressure.
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2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male plug in hose fitting 6 and close the shut-off valve 7 .
The air receiver pressure gauge does not read 0 psig after venting?

10 Maintenance
10.14 Changing the cooling oil
Result The machine is fully depressurized when both pressure gauges 2 and 9 show 0 psig after manual
venting.
10.13.2 Topping off with cooling oil and test run

Replenishing cooling oil
A sticker on the oil separator tank specifies the type of oil used.
1. Compressed air!
Compressed air and components under pressure can injure or cause death if the contained en‐
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ergy is suddenly released.
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2. The machine could be damaged by unsuitable oil!
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➤ Never mix different types of oil.
➤ Never top off with a different type of oil to that already used in the machine.
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3. Slowly unscrew the filler plug 4 .
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4. Top off to bring the oil to the correct level.
5. Replace the filler plug's sealing ring if necessary and screw the plug into the filler port.
Starting the machine and performing a test run

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1. Close the enclosure.
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3. Start the machine and check the oil level again after approx. 10 minutes of operation, top off if
necessary.
4. Switch off the machine and check for leaks.
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Always drain the oil completely from the following components:

■ Airend
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■ Oil separator tank

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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):

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■ The machine is not operational.

■ The machine is to be restarted after a long period of standstill.
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Material Cooling oil

Cooling oil receptacle
The maintenance hose with hose coupling and shut-off valve is stowed inside the machine.

10 Maintenance
There is risk of burns from hot components and cooling oil!

➤ Wear long-sleeved garments and gloves.
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Fig. 31 Changing the cooling oil, oil separator tank

1 Hose coupling (air receiver venting) A Shut-off valve open
2 Pressure gauge B Shut-off valve closed
3 Hose coupling (oil separator tank pressure 8 Maintenance hose
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relief) 9 Hose coupling (oil drain)

4 Cooling oil inlet port with screw plug 10 Shut-off valve (control line)
5 Cooling oil level indicator 11 Shut-off valve (oil drain)
6 Plug-in hose fitting
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7 Shut-off valve
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10 Maintenance
Changing the cooling oil with internal pressure Oil change with an external compressed air
source
The machine has been running for at least 5 mi‐ The power supply disconnecting device is
nutes in LOAD mode. switched off,
The machine is completely vented to atmos‐ lockout and tagout the device,
pheric pressure, verify the absence of any voltage.
i.e. both pressure gauges 2 and 9 (see Fig 29) The machine is completely vented to atmos‐
are showing 0 psig. pheric pressure,
1. Close the shut-off valve 10 in the venting i.e. both pressure gauges 2 and 9 (see Fig 29)
line. are showing 0 psig.
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2. Start the machine and watch the oil separa‐ An external source of compressed air is availa‐
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tor tank pressure gauge 2 until it reads 43– ble.
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73 psig. 1. Close the shut-off valve 10 in the venting
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3. Switch off the machine. line.
4. Wait at least 2 minutes to allow the oil to 2. With the shut-off valve closed, insert the
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flow back to the separator tank. plug-in hose fitting 6 into the hose cou‐
pling 3 .
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3. Connect the maintenance hose to the exter‐
nal air supply.
4. Open the shut-off valve 7 until the pressure
gauge 2 on the oil separator tank reads 43–
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73 psig.
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5. Close the shut-off valve 7 and remove the

plug-in nozzle from the hose coupling.
Draining the cooling oil from the airend

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➤ Turn the belt pulley only in the direction of the indicating arrow on the airend.
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Fig. 32 Removing/replacing the belt guard

Screw plug
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1
2 Belt guard
3 Belt pulley
1. Unscrew both screw plugs 1 and remove the belt guard 2 .

2. Manually turn the belt pulley 3 in full at least 5 times to drain the remaining cooling oil from the
airend into the oil separator tank.
3. Replace the belt guard and screw plugs.

10 Maintenance
10.15 Changing the oil filter
Draining the cooling oil from the separator tank
Contact an authorized KAESER service representative if condensate is detected in the oil.

It is necessary to adapt the airend discharge temperature to individual ambient conditions.

lockout and tagout the device,
1. Prepare a cooling oil receptacle.

2. With the shut-off valve closed, insert the plug-in hose fitting 6 into the hose coupling 9 .
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3. Place the other end of the maintenance hose in the oil receptacle and secure it in place.
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4. Open the shut-off valve 11 .
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5. Slowly open the shut-off valve 7 in the maintenance hose and allow oil and air to drain com‐
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pletely.
Pressure gauge on the oil separator tank indicates 0 psig.
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6. Close the shut-off valve 11 and unplug the male plug-in hose fitting.
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➤ Dispose of used oil in accordance with environment protection regulations.
Filling with cooling oil

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1. Compressed air!
Compressed air and components under pressure can injure or cause death if the energy con‐
tained within is suddenly released.
2. Slowly unscrew the filler plug 4 (see Fig. 31).
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3. Fill with cooling oil.

4. Check the screw plug ring seal for damage and screw the filler neck with the screw plug back
in again.
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Starting the machine and performing a trial run

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1. Replace the belt guard and close the enclosure.

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3. Switch on the electrical power supply via the power supply disconnecting device and reset the
maintenance interval counter.
4. Start the machine and check the cooling oil level again after about 10 minutes, topping up if
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necessary.
5. Switch off the machine and visually check for leaks.
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The machine must be fully isolated from the compressed air network and completely vented
before undertaking any work on the pressure system.
All the cooling oil has run out of the filter 1–2 minutes after shutting down. A cooling oil receptacle
is not needed.

10 Maintenance
Material Spare parts

Cleaning cloths

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!
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➤ Wear long-sleeved clothing and protective gloves.
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Fig. 33 Changing the oil filter

1 Oil filter
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2 Direction to unscrew
3 Oil separator cartridge
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Changing the oil filter

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1. Unscrew the oil filter counterclockwise and wipe off any drops of oil.
2. Lightly oil the new filter's gasket.
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3. Turn the oil filter clockwise by hand to tighten.

➤ Dispose of parts and material contaminated with oil according to environment protection
regulations.
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1. Close the enclosure.

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2. Open the user's shut-off valve between the machine and the air distribution network.
3. Switch on the power supply and reset the maintenance interval counter.
4. After approx. 10 minutes of operation: Check the cooling oil level and top off if necessary.
5. Switch off the machine and check for leaks.

10 Maintenance
10.16 Changing the oil separator cartridge
10.16 Changing the oil separator cartridge

The machine must be fully isolated from the compressed air network and completely vented
before undertaking any work on the pressure system.
The life of the oil separator cartridge is influenced by:

■ Contamination in the air drawn into the compressor,
■ Adherence to the changing intervals for the:
─ Cooling oil
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─ Oil filter
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─ Air filter
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All the cooling oil has run out of the separator cartridge 1–2 minutes after shutting down. A cooling
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oil receptacle is not needed.
Material Spare parts

Cleaning cloths
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The machine is fully vented at atmospheric pressure, the pressure gauge on the oil separator tank
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reads 0 psig.
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There is risk of burns from hot components and oil!

➤ Wear long-sleeved clothing and protective gloves.
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Fig. 34 Changing the oil separator cartridge

1 Oil filter
2 Direction to unscrew
3 Oil separator cartridge
Changing the oil separator cartridge
1. Unscrew the oil separator cartridge counterclockwise and wipe off any drops of oil.

10 Maintenance
10.17 Maintaining the refrigerated dryer
2. Lightly oil the new filter's gasket.

3. Turn the oil filter clockwise by hand to tighten.
➤ Dispose of parts and material contaminated with cooling oil according to environmental
protection regulations.
1. Replace the enclosure.

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3. Switch on the power supply and reset the maintenance interval counter.
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4. Start the machine and run it for 10 minutes, then stop it and visually check for leaks.
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Repairs may only be carried out by certified personnel.
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Material Compressed air for blowing out
Cleaning cloth
Vacuum cleaner
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Fig. 35 Refrigerated dryer

1 Sight glass: Condensate drain
2 Condensate drain
3 Refrigerant condenser
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10.17.1 Cleaning the refrigerant condenser

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

1. Brush dirt from the refrigerant condenser 3 and vacuum up.

2. Blow out as required with compressed air (<30 psig!).

10 Maintenance
The refrigerant condenser can't be cleaned thoroughly?

➤ Have severe clogging removed by an authorized KAESER service representative.
10.17.2 Maintaining the condensate drain

10.17.2.1 Checking the condensate drain
Precondition The power supply disconnecting device is switched on.

Condensate drain is pressurized.
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The Power LED lights.
The sight glass is removed.
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Fig. 36 Checking the condensate drain
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1 Power LED
2 «TEST» key
1. Danger of burns from hot components near the condensate drain!

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➤ Work with caution.

2. With one hand, lightly touch the condensate line at the condensate drain.
3. With your other hand, push and hold the «TEST» key at the condensate drain for at least
2 seconds.
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Result As soon as the condensate drain opens, you will feel a short burst at the condensate line.
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Service the condensate drain if you do not experience a burst during manual test.
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10.17.2.2 Changing the service unit
The condensate drain cannot be cleaned. The service unit must be changed if condensate does
not drain.
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Material Sealing tape for sealing the screw-in part

If required: O-ring 16x2 (5.1519.0)
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10 Maintenance
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Fig. 37 Changing the service unit
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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
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6 Condensate drain hose fitting 13 Union nut with vent holes

7 Contact springs 14 Insulation
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Removing the service unit
1.
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Serious injury or death can result from loosening or opening components under
pressure!
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2. Close the shut-off valve 9 upstream of the condensate drain.
3. Unscrew the drain hose fitting 6 at the condensate line.
4. Press the snap fastener 5 and carefully remove the control module 2 from the service unit 1 .
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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.
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7. Remove the insulation 14 from the service unit.
Installing the service unit
Use only genuine 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 .

10 Maintenance
10.18 Air receiver maintenance
2. Carefully insert the sensor 3 of the control module 2 in the opening 4 of the service unit.
3. Place the snap fastener 5 of the control module into the service unit eyes.
4. Press the control module against the service unit until the snap fastener can be heard clicking
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.
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10. Open the shut-off valve upstream of the condensate drain.
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11. Replace the enclosure.
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Condensate is removed automatically by the refrigerated dryer's condensate drain. A dirt trap pro‐
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tects the condensate drain from contamination that would impair its function. The condensate drain
only functions when the dryer is in operation.
➤ Condensate can be drained manually from the air receiver when the dryer is not operat‐
ing.
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Material If required:
Dirt trap strainer
O-ring
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Fig. 38 Air receiver maintenance

1 Dirt trap A Shut-off valve open
2 Strainer B Shut-off valve closed
Screw plug Maintenance hose
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3 8
4 O-ring 9 Hose coupling (condensate drainage)
6 Male plug in hose fitting 11 Shut-off valve (condensate drainage)
7 Shut-off valve
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Cleaning the dirt trap

User's shut-off valve between the machine and the air network is closed.
The machine is completely vented to atmospheric pressure,

10 Maintenance
1. Remove the screw plug 3 .

2. Remove and clean the O-ring 4 .
3. Remove the strainer 2 and blow clean with compressed air.
4. Insert the strainer and replace the O-ring and plug.
Replace the strainer and/or O-ring if necessary.
Manually draining the condensate
Precondition The air receiver is pressurized.
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Wear eye and hearing protection.
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2. Open the shut-off valve 11 .
3. Slowly open the shut-off valve 7 in the maintenance hose and allow the condensate to drain
completely.
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All condensate is drained when only compressed air is blown out.
4. Close the shut-off valve 11 and unplug the male plug in hose fitting.
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10 Maintenance
10.19 Documenting maintenance and service work
10.19 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
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Tab. 46 Logged maintenance tasks

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
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KAESER spare parts and operating materials are all genuine KAESER parts. They are specifically
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designed for use in KAESER machines.
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Unsuitable or poor quality spare parts and operating fluids/materials may result in damage to the
machine or significantly impair its proper function.
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Damage to the machine can also result in personal injury.
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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.
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➤ Have an authorized KAESER service representative carry out regular maintenance.
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Name Number
Air filter cartridge 1250
Filter mat 1050
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Oil filter 1200

Oil separator cartridge 1450
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Cooling oil 1600

Drive belt 1802
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Condensate drain: 9602

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Service module
Tab. 47 Spare parts
11.3 KAESER AIR SERVICE

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KAESER AIR SERVICE offers:

■ authorized KAESER service representatives with KAESER factory training,
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■ increased operational reliability ensured by preventive maintenance,

■ energy savings achieved by avoidance of pressure losses,
■ 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!

11.4 Replacement parts for service and repair
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
an authorized KAESER Service represenstative.
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SEG-5405_01
Kondensatableiter / Condensate drain
Service-Kit
( Option )
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6307
9022
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9603
9602

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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.
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➤ The following tasks are to be performed by authorized personnel only.
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12.1.1 Temporary decommissioning
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Precondition The machine can be started at regular intervals.
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➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protec‐
tion against corrosion.
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12.1.2 Long-term decommissioning
Precondition Immediately prior to decommissioning, run the machine under LOAD for at least 30 minutes.
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12.1.2.1 Draining condensate
If the machine is equipped with a condensate drain, drain condensate from the condensate drain.
Precondition The power supply disconnecting device is switched off.

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1. Drain condensate from the condensate drain and dispose of according to applicable environ‐
mental protection regulations.
2. Remove the user-supplied condensate lines.
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The condensate drains are not supplied with power when the machine is switched off?
➤ Detach and drain the condensate drains.
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12.1.2.2 Isolating the machine from supply lines
Precondition The power supply isolating device is switched off,

it has been locked out and tagged out against unintentional reactivation and
the absence of voltage has been verified.
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The machine is fully vented (depressurized).

The user's shut-off valve to the compressed air network is closed or the compressed air network
has been fully vented.
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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. Properly close all open connecting ports.
12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.

12.3 Storage
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.
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2. Wrap the machine fully in plastic sheeting.
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3. Protect the machine in a wooden crate against mechanical damages.
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12.3 Storage
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Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator
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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‐
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sioning.
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1. Moisture and frost can damage the machine!

➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >32 °F.
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2. Store the machine in a dry, frost-proof room.
12.4 Transport
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12.4.1 Safety
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Weight and center of gravity determine the most suitable method of transportation. The center of
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gravity is shown in the drawing in chapter 13.2.

➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐
tures.
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Precondition Transport only by forklift truck or suitable lifting gear and only by personnel trained in the safe
transportation of loads.
➤ Ensure the danger area is clear of personnel.

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12.4.2 Transport with a forklift truck

Precondition The forks are fully under the machine.

12.4 Transport
Fig. 39 Transport with a forklift truck
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1. Machine damage caused by an unsecured enclosure.
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➤ Prior to transporting, remove the enclosure and transport separately.
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2. Take note of the center of gravity.
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3. Drive the forks completely under the machine or pallet and lift carefully.
12.4.3
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Transport with a crane
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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.
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Examples of unsuitable fixing points:
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■ Pipe sockets
■ Flanges
■ Attached components such as centrifugal separators, condensate drains, or filters
■ Rain protection covers
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➤ Consult KAESER if you require suitable load-carrying and attachment devices or have
questions regarding the correct use.
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Precondition Load-carrying and attachment devices meet the local safety regulations.
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The crane, load-carrying and attachment devices or the lifted machine do not endanger personnel.
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12.4 Transport
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Fig. 40 Transporting with a crane
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1 Load carrying devices

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

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ces!
➤ Comply with permissible load limits.
➤ Comply with specific safety information of used load-carrying and attachment devices.
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2. Properly use load-carrying and attachment devices:

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■ Ensure proper distribution of the fixing points relative to the center of gravity position (sym‐
metrical load distribution).
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■ 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.
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■ 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.
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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.

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‐
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ment protection regulations.
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Compressors with refrigeration dryers
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The refrigerant circuit still contains both refrigerant and oil.
➤ Refrigerant and oil must be drained and disposed of by authorized personnel.
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12.5.1 Battery disposal in accordance with local environmental regulations.
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
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of batteries.
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The SIGMA CONTROL 2controller’s enclosure houses a battery.

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Fig. 41 Battery labelling

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1 Do not dispose of batteries with residential waste.

2 Battery contains lead (if applicable)
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➤ Comply with national disposal regulations and dispose of batteries in an environmentally-

friendly manner.
You actively contribute to the protection of our environment when you bring used batteries to
the appropriate recycling system.
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Further information Refer to the SIGMA CONTROL 2user manual for details regarding battery removal and replace‐
ment.
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13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)
13 Annex
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13 Annex
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13 Annex
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13 Annex
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13 Annex
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13 Annex
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13 Annex
13.2 Dimensional Drawing
13.2 Dimensional Drawing
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Die Zeichnung bleibt unser ausschließliches Eigentum. Sie wird nur zu dem vereinbarten Zweck anvertraut und darf zu keinem anderen Zweck verwendet werden. Drawings remain our exclusive property. They are entrusted only for the agreed purpose. Copies or any other reproduction, including storage, treatment and Entwicklungsbedingte Änderungen
Kopien oder sonstige Vervielfältigungen einschließlich Speicherung, Verarbeitung oder Verbreitung unter Verwendung elektronischer Systeme dürfen nur zu dem dissemination by use of electronic systems must not be made for any other than the agreed purpose. Neither originals nor reproductions may be given to or made vorbehalten. Zeichnung darf nur über CAD
vereinbarten Zweck angefertigt werden. Weder Original noch Vervielfältigungen dürfen Dritten ausgehändigt oder in sonstiger Weise zugänglich gemacht werden. available to third parties. geändert werden.
Option:
Air cooling
5 5/8
Machine mountings
1 1/8
Condensate drain NPT 1/4

Condensate drain NPT 1/4
Su 8 7/8
Air discharge
10 3/8
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4
Y
Air discharge NPT 3/4
11 1/8
44 1/8 9
K1
H1
Code:
ec
PR
tt
Air discharge
2 1/2
Cooling air outlet
2 1/4
ATTENTION!
Y
Electrical connections
CG : Centre of gravity
CG
EL
15
19 3/8
24 3/8
1/8
1 3/4
11 3/4
7 3
position marginally dependent on design

IM
I
Minimum width of door is total width of unit + 100 mm

Cooling air inlet
is
o NA
Status
Änderungs-Nr.
Dokument TZD
Dokument TZM
io
FREIGEGEBEN
R R
10219789 D 00
10219789 USE 00
Projektion
n
58
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A3
Original
35 5/8 7 7/8
Maßstab
Bezeichnung
27 1/2
3 3/4
Gez.
SXC.2 K1
Bearb.
Dimension and connection dim.

6 1/2
All Dimensions are in inches!

Datum
11
d i a. 3 7/8
13 1/4
3 7/
8
Freigeg. 12.04.2012 SCHUBT4

12.04.2012 ROEBLITZ1
04.04.2012 ROEBLITZ1
Z
CG
d ia
Name
. 1/
38 5/8
2
33 7/8
28 1/8
H1
USE
Sprache
1/8
1 1/2
5 1/2
Blatt
6 3/4
5 1/2
1 von 1
02.02.2012
Dimensional Drawing 13.2
Annex 13
13 Annex
13.3 Electrical Diagram
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n
R R
io
o NA
is
I
IM
EL
tt
PR
ec
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1 2 3 4 5 6 7 8
9_6917 43 USE
Wiring Diagram
ATTENTION !!! AIRTOWER 3C/4C/5C/7.5C
The unit is non-functional when delivered.
Before connecting the electrical supply,
PR
13
please follow the advice contained

13.3
Three-phase power supply for the compressor

Su
in the 'Installation' chapter and
208V±10% 3ph 60Hz 230V±10% 3ph 60Hz
the wiring diagram of the service manual.
460V±10% 3ph 60Hz
Tri-Voltage
Annex
Power supply:
bj EL
WYE system with center point solidly grounded
Electrical Diagram
Single-phase power supply for the refrigeration dryer

ec IM
The integrated refrigeration dryer requires if necessary

ATTENTION !!!
The document gives collective information on a separate power supply.
power supply voltages and frequencies for all machines. Note instructions on sheet 1 of the electrical diagrams.
The voltage and frequency and local conditions under
which any particular machine may be used
are given on the nameplate of the machine
tt I 115V±10% 1ph 60Hz
and in the accompanying service manual. single phase system with solidly grounded end of phase
manufacturer: KAESER COMPRESSORS

o NA
96450 COBURG
GERMANY
R R
The drawings remain our exclusive property. They are entrusted
only for the agreed purpose. Copies or any other reproductions,
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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.
is
c Date 13.03.2019 USE cover page =
b Drawn Taubmann +
a Released Büchner
AIRTOWER 3C/4C/5C/7.5C page 1
SC2 MCSIO DSXC-U3107.00
A Change Date Name 1 Sht.
io
103
n
104
Lfd. Nr. Benennung Zeichnungsnummer (Kunde) Zeichnungsnummer (Hersteller) Blatt Anlagenkennzeichen
No. Name Drawing No. (customer) Drawing No. (manufacturer) Page Unit designation
1 cover page DSXC-U3107.00 1
2 list of contents ZSXC-U3107.00 1
3 general instructions USXC-U3107.00 1
4 electrical component parts list USXC-U3107.00 2
5 electrical component parts list USXC-U3107.00 3
6 wiring diagram power supply, refrigeration dryer SSXC-U3107.00 1
7 wiring diagram power unit SSXC-U3107.00 2
8 wiring diagram control SSXC-U3107.00 3
13
13.3
PR
9 wiring diagram air dryer control SSXC-U3107.00 4
10 wiring diagram control voltage tapping SSXC-U3107.00 5
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11 wiring diagram power supply unit SSXC-U3107.00 6
12 wiring diagram IO-module configuration SSXC-U3107.00 7
13 wiring diagram sensors/actuators SSXC-U3107.00 8
14 wiring diagram volt-free contacts SSXC-U3107.00 9
Annex
15 wiring diagram inputs/outputs SSXC-U3107.00 10

16 wiring diagram transformer diagrams SSXC-U3107.00 11
17 wiring diagram Handling: Terminals/Feed line connection SSXC-U3107.00 12
bj EL
18 terminal connection terminal strip -X01,-X1 KSXC-U3107.00 1
Electrical Diagram
19 terminal connection terminal strip -X11,-X30,-X31,-3X31 KSXC-U3107.00 2

20 lay-out Switchboard ASXC-U3107.00 1

ec IM
tt I
o NA
R R
ev Y
c Date 13.03.2019
is list of contents =
b Drawn Taubmann +
a Released Büchner
B Change Date Name
SC2 MCSIO ZSXC-U3107.00 1 Sht.
io
9_6917 43 USE
n
1 2 3 4 5 6 7 8
general instructions
9_6917 43 USE
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 control voltage AC 115V grounded: white, 18AWG UL-Style 1015, CSA-TEW
live plug-in connectors.
PR
control voltage DC ungrounded: blue, 18AWG UL-Style 1015, CSA-TEW
13
13.3
control voltage DC grounded: white/blue, 18AWG UL-Style 1015, CSA-TEW

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external voltage: orange, 16AWG UL-Style 1015, CSA-TEW
measuring circuits: violet, 18AWG UL-Style 1015, CSA-TEW
ground conductor: green/yellow, UL-Style 1015, CSA-TEW
Annex
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Electrical Diagram
electrical equipment identification

ec IM
general components control terminal strips/plug-in connections

-B25 overload relay compressor motor -K20 SIGMA CONTROL 2 MCSIO -X01,-X02 terminal strip power supply
-C4 capacitor vent motor Oil cooler -X1 Ethernet -X1 terminal strip motor
-1FU,-2FU primary control fuse -X4 RS485-FC (USS) -X11 terminal strip control
-3FU
-M1
secondary control fuse
compressor motor
tt
-X5
-X6
I
SD card slot
ground connection
-X30, -X31 terminal strip refrigeration dryer
-M4 vent motor Oil cooler -X7 power supply unit, digital inputs -3X31 terminalbox refrigeration dryer
-Q1 main contactor -X8 digital inputs, digital outputs
-Q2 delta contactor -X9 analog inputs, 4-20mA, Pt100
-Q3 wye contactor -X10 Relay outputs sensors/actuators
o NA
-Q4 motor starter vent motor oil cooler -B1 pressure transducer Network pressure
-S1 EMERGENCY STOP pushbutton -B2 safety air pressure switch-direction of rotation
-T11 control transformer -B30 safety pressure controller
-T21 power unit -B40 temperature probe airend discharge temperature
R R
-K1 bypass valve
refrigeration dryer
-4FU fuses
-K34 condensate drain
-M30 compressor motor
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-M31 vent motor
-Q30 motor starter
-P34 indicating light mains voltage refrigeration dryer
is
c Date 13.03.2019 general instructions =
b Drawn Taubmann +
a Released Büchner
SC2 MCSIO USXC-U3107.00
C Change Date Name 3 Sht.
io
105
n
13 Annex
electrical component parts list
2
3 Sht.
page
model
AIRTOWER 3 C AIRTOWER 4 C AIRTOWER 5 C AIRTOWER 7.5 C
machine power supply 208 V ±10 %, 60 Hz 208 V ±10 %, 60 Hz 208 V ±10 %, 60 Hz 208 V ±10 %, 60 Hz
230 V ±10 %, 60 Hz 230 V ±10 %, 60 Hz 230 V ±10 %, 60 Hz 230 V ±10 %, 60 Hz
USXC-U3107.00
+
=
motor -M1 3 hp 4 hp 5 hp 7,5 hp
diagram 1, Sht. 2 (208+ 230 V) diagram 1, Sht. 2 (208+ 230 V) diagram 1, Sht. 2 (208+ 230 V) diagram 1, Sht. 2 (208+ 230 V)
supply terminals -X01:1U/1V/1W 7.3149.01890 7.3149.01890 7.3149.01890 7.3149.01890
Wieland WKFN6D1/2/35 WKFN6D1/2/35 WKFN6D1/2/35 WKFN6D1/2/35
Stripped length 12 mm 12 mm 12 mm 12 mm
Handling fig. 2, Sht. 12 fig. 2, Sht. 12 fig. 2, Sht. 12 fig. 2, Sht. 12
-X01:GRD 7.3149.01910 7.3149.01910 7.3149.01910 7.3149.01910
Wieland WKFN6D1/2/SL/35 WKFN6D1/2/SL/35 WKFN6D1/2/SL/35 WKFN6D1/2/SL/35
SC2 MCSIO
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-X02:2U / -4FU 7.3320.00050 7.3320.00050 7.3320.00050 7.3320.00050
Wieland AMBUS EASYSWITCH AMBUS EASYSWITCH AMBUS EASYSWITCH AMBUS EASYSWITCH
n
Torque 22 lb-in 22 lb-in 22 lb-in 22 lb-in
R R
-X02:N 7.3149.01810 7.3149.01810 7.3149.01810 7.3149.01810
io
Wieland WKFN4/35 WKFN4/35 WKFN4/35 WKFN4/35
AIRTOWER 3C/4C/5C/7.5C
-X02:GRD
Wieland
7.3149.01830
WKFN4SL/35
o NA
7.3149.01830
WKFN4SL/35
7.3149.01830
WKFN4SL/35
7.3149.01830
WKFN4SL/35
is

supply connection fig. 10, Sht. 12 fig. 10, Sht. 12 fig. 10, Sht. 12 fig. 10, Sht. 12
terminal strip -X01 7.6836.00310 Wieland 7.6836.00310 Wieland 7.6836.00310 Wieland 7.6836.00310 Wieland
terminal strip -X11/-X30/-X31 7.6836.00830 Wieland 7.6836.00830 Wieland 7.6836.00830 Wieland 7.6836.00830 Wieland
contactor -Q1/-Q2/-Q3 7.8740.00350 7.8740.00350 7.8740.00360 7.8740.00360
I
3RT2024-1AK60 3RT2024-1AK60 3RT2025-1AK60 3RT2025-1AK60
IM
interference suppressor 7.8740.05140 7.8740.05140 7.8740.05140 7.8740.05140

Siemens 3RT2926-1CC00 3RT2926-1CC00 3RT2926-1CC00 3RT2926-1CC00
auxiliary switch -Q1 7.8740.05010 7.8740.05010 7.8740.05010 7.8740.05010
3RH2911-1HA11 3RH2911-1HA11 3RH2911-1HA11 3RH2911-1HA11
contactor -Q4 7.8740.00310 7.8740.00310 7.8740.00310 7.8740.00310
EL

contactor -Q30 7.8740.03010 7.8740.03010 7.8740.03010 7.8740.03010
Siemens 3RT2016-1JB41 3RT2016-1JB41 3RT2016-1JB41 3RT2016-1JB41
overload relay -B25 7.8741.00060 7.8741.00060 7.8741.00060 7.8741.00070
3RB3026-1SB0 (3-12 A) 3RB3026-1SB0 (3-12 A) 3RB3026-1SB0 (3-12 A) 3RB3026-1QB0 (6-25 A)
tt
setting: 4,6 A (208 V) setting: 6,2 A (208 V) setting: 8,3 A (208 V) setting: 10,9 A (208 V)
PR
NEC 430.32(C) incremental NEC 430.32(C) incremental NEC 430.32(C) incremental NEC 430.32(C) incremental
Siemens setting: 4,8 A (230 V) setting: 6,5 A (230 V) setting: 9,3 A (230 V) setting: 11,6 A (230 V)
ec
fuses -1FU...-3FU 7.3316.1 7.3316.1 7.3316.1 7.3316.1

Gould ATQR 1 1/2 (1,5 A, 600 V) ATQR 1 1/2 (1,5 A, 600 V) ATQR 1 1/2 (1,5 A, 600 V) ATQR 1 1/2 (1,5 A, 600 V)
fuses -4FU 7.3306.00010 7.3306.00010 7.3306.00010 7.3306.00010
Gould ATDR 7 (7 A, 600 V) ATDR 7 (7 A, 600 V) ATDR 7 (7 A, 600 V) ATDR 7 (7 A, 600 V)
fuse socket -1FU...-3FU 7.3320.00060 7.3320.00060 7.3320.00060 7.3320.00060
Wöhner AMBUS EASYSWITCH AMBUS EASYSWITCH AMBUS EASYSWITCH AMBUS EASYSWITCH
bj
fuse socket -4FU 7.3320.00050 7.3320.00050 7.3320.00050 7.3320.00050

transformer -T11 7.2221.10030 7.2221.10030 7.2221.10030 7.2221.10030
Block B0406056 (160 VA) B0406056 (160 VA) B0406056 (160 VA) B0406056 (160 VA)
power supply -T21 7.7605P0 7.7605P0 7.7605P0 7.7605P0
Su
13.03.2019
Taubmann
Büchner
Prodrive PSDC24/2.5 PSDC24/2.5 PSDC24/2.5 PSDC24/2.5

cables -W19.1 7G14 AWG 7G14 AWG 7G12 AWG 7G12 AWG
-W19.2 6x14 AWG 6x14 AWG 6x12 AWG 6x12 AWG
600 V, 90°C 600 V, 90°C 600 V, 90°C 600 V, 90°C
Released
Drawn
Date
compressor control -K20 7.9700.0 7.9700.0 7.9700.0 7.9700.0

Prodrive SIGMA CONTROL 2 MCSIO SIGMA CONTROL 2 MCSIO SIGMA CONTROL 2 MCSIO SIGMA CONTROL 2 MCSIO
Name
EMERGENCY STOP pushbutton -S1 7.3217.0 / QRUV 7.3217.0 / QRUV 7.3217.0 / QRUV 7.3217.0 / QRUV
auxiliary contact Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO
indicator light -P34 7.5720.0 7.5720.0 7.5720.0 7.5720.0
Date
CML 19511331KAE 19511331KAE 19511331KAE 19511331KAE

capacitor -C4 7.7547.0 7.7547.0 7.7547.0 7.7547.0
ebm-papst MKP 5µF MKP 5µF MKP 5µF MKP 5µF
C Change
b
a
c

13 Annex
3
3 Sht.
page
model
AIRTOWER 3 C AIRTOWER 4 C AIRTOWER 5 C AIRTOWER 7.5 C
machine power supply 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz
USXC-U3107.00
motor -M1 3 hp 4 hp 5 hp 7,5 hp
+
=
diagram 2, Sht. 2 (460 V) diagram 2, Sht. 2 (460 V) diagram 2, Sht. 2 (460 V) diagram 2, Sht. 2 (460 V)
supply terminals -X01:1U/1V/1W 7.3149.01890 7.3149.01890 7.3149.01890 7.3149.01890
Wieland WKFN6D1/2/35 WKFN6D1/2/35 WKFN6D1/2/35 WKFN6D1/2/35
-X01:GRD 7.3149.01910 7.3149.01910 7.3149.01910 7.3149.01910
Wieland WKFN6D1/2/SL/35 WKFN6D1/2/SL/35 WKFN6D1/2/SL/35 WKFN6D1/2/SL/35
-X02:2U / -4FU 7.3320.00050 7.3320.00050 7.3320.00050 7.3320.00050
SC2 MCSIO
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Wieland AMBUS EASYSWITCH AMBUS EASYSWITCH AMBUS EASYSWITCH AMBUS EASYSWITCH
Torque 22 lb-in 22 lb-in 22 lb-in 22 lb-in
n
-X02:N 7.3149.01810 7.3149.01810 7.3149.01810 7.3149.01810
R R
Wieland WKFN4/35 WKFN4/35 WKFN4/35 WKFN4/35
io
-X02:GRD 7.3149.01830 7.3149.01830 7.3149.01830 7.3149.01830
Wieland
Stripped length
WKFN4SL/35
11 mm
o NA
WKFN4SL/35
11 mm
WKFN4SL/35
11 mm
WKFN4SL/35
11 mm
is

supply connection fig. 10, Sht. 12 fig. 10, Sht. 12 fig. 10, Sht. 12 fig. 10, Sht. 12
terminal strip -X01 7.6836.00310 Wieland 7.6836.00310 Wieland 7.6836.00310 Wieland 7.6836.00310 Wieland
terminal strip -X11/-X30/-X31 7.6836.00830 Wieland 7.6836.00830 Wieland 7.6836.00830 Wieland 7.6836.00830 Wieland
contactor -Q1/-Q2/-Q3 7.8740.00350 7.8740.00350 7.8740.00360 7.8740.00360
I
IM

auxiliary switch -Q1 7.8740.05010 7.8740.05010 7.8740.05010 7.8740.05010
3RH2911-1HA11 3RH2911-1HA11 3RH2911-1HA11 3RH2911-1HA11
contactor -Q4 7.8740.00310 7.8740.00310 7.8740.00310 7.8740.00310
EL
contactor -Q30 7.8740.03010 7.8740.03010 7.8740.03010 7.8740.03010

Siemens 3RT2016-1JB41 3RT2016-1JB41 3RT2016-1JB41 3RT2016-1JB41
overload relay -B25 7.8741.00120 7.8741.00060 7.8741.00060 7.8741.00060
3RB3026-1PB0 (1-4 A) 3RB3026-1SB0 (3-12 A) 3RB3026-1SB0 (3-12 A) 3RB3026-1SB0 (3-12 A)
setting: 2,1 A setting: 2,9 A setting: 4,2 A setting: 5,2 A
tt
NEC 430.32(C) incremental NEC 430.32(C) incremental NEC 430.32(C) incremental NEC 430.32(C) incremental
Siemens setting: 2,4 A setting: 3,3 A setting: 4,7 A setting: 5,8 A
PR
fuses -1FU...-3FU 7.3316.1 7.3316.1 7.3316.1 7.3316.1

Gould ATQR 1 1/2 (1,5 A, 600 V) ATQR 1 1/2 (1,5 A, 600 V) ATQR 1 1/2 (1,5 A, 600 V) ATQR 1 1/2 (1,5 A, 600 V)
fuses -4FU 7.3306.00010 7.3306.00010 7.3306.00010 7.3306.00010
ec
Gould ATDR 7 (7 A, 600 V) ATDR 7 (7 A, 600 V) ATDR 7 (7 A, 600 V) ATDR 7 (7 A, 600 V)

fuse socket -1FU...-3FU 7.3320.00060 7.3320.00060 7.3320.00060 7.3320.00060
fuse socket -4FU 7.3320.00050 7.3320.00050 7.3320.00050 7.3320.00050
transformer -T11 7.2221.10030 7.2221.10030 7.2221.10030 7.2221.10030
bj
Block B0406056 (160 VA) B0406056 (160 VA) B0406056 (160 VA) B0406056 (160 VA)
power supply -T21 7.7605P0 7.7605P0 7.7605P0 7.7605P0
Prodrive PSDC24/2.5 PSDC24/2.5 PSDC24/2.5 PSDC24/2.5
cables -W19.1 7G14 AWG 7G14 AWG 7G12 AWG 7G12 AWG
600 V, 90°C 600 V, 90°C 600 V, 90°C 600 V, 90°C
Su
13.03.2019
Taubmann
Büchner
cables -W19.2 6x14 AWG 6x14 AWG 6x12 AWG 6x12 AWG
600 V, 90°C 600 V, 90°C 600 V, 90°C 600 V, 90°C
compressor control -K20 7.9700.0 7.9700.0 7.9700.0 7.9700.0
Prodrive SIGMA CONTROL 2 MCSIO SIGMA CONTROL 2 MCSIO SIGMA CONTROL 2 MCSIO SIGMA CONTROL 2 MCSIO
Released
Drawn
Date
EMERGENCY STOP pushbutton -S1 7.3217.0 / QRUV 7.3217.0 / QRUV 7.3217.0 / QRUV 7.3217.0 / QRUV
auxiliary contact Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO
Name
indicator light -P34 7.5720.0 7.5720.0 7.5720.0 7.5720.0

CML 19511331KAE 19511331KAE 19511331KAE 19511331KAE
capacitor -C4 7.7547.0 7.7547.0 7.7547.0 7.7547.0
Date
ebm-papst MKP 5µF MKP 5µF MKP 5µF MKP 5µF

C Change
b
a
c

108
1 2 3 4 5 6 7 8
1L1
/2.1
1L2
/2.1
1L3
/2.1
11L1
/5.1
11L2
/5.1
GRD
/2.1
12AWG green/yellow
600V 90°C
GRD2
1GRD
13
-X01 -X11 GRD1 -X11

13.3
PR
X2
-P34
Su
14AWG
mains voltage air dryer
X1
grey
green
600V 90°C
10AWG green/yellow
18AWG
600V 90°C 14AWG
Annex
18AWG
1GRD
-X01 red
stickers on outside black red 18AWG
600V 90°C
of cabinet 600V 90°C 600V 90°C white
EL
-X30 600V 90°C
bj
control panel 1
Warning!
Mortal danger from multiply power supplies! 10AWG green/yellow -X30
Electrical Diagram

600V 90°C
2
6
-Q30
1GRD
Touching electrically live components can cause -X01
18AWG

serious injury or death. More than one disconnect /4.4
ec IM
1
5
unit frame
white
switch may be required to de-energize the
600V 90°C
1
2
GNYE
equipment before servicing. -W179 -W179

oil separator
7A Class CC
2
Isolate the machine from all power phases. 5G14AWG 5G14AWG
pivoting motor base
14AWG
600V 90°C 600V 90°C
green/yellow
1GRD
2GRD
2N
-X01
-X02
-X02
-4FU
I distribution terminal box in the dryer -3X31 GRD
600V 90°C
1V
1U
1W
tt
3 wire + 1 ground 2 wire + 1 ground
2U
power supply cable power supply cable -3X31 1 -3X31 1 -3X31 1
for compressor for refrigerated dryer N N N base plate air dryer
-F0.1 GRD GRD
-F0.2
o NA
15A Class J
-W170 -W171 -W80
main disconnect,
2
4
6
8
10
-Q0 3G14AWG 3G18AWG 2x18AWG
fuse supplied
600V 90°C 600V 90°C 600V 90°C
by user
R R
L/+
N/-
1
3
5
7
9
For field wiring:
L1
L2
GRD
L1
L2
GRD
-K34
Use 75°C copper
supply line cross-section ande conductors only! M M
2N
fusing see operating manual
1L1
1L2
1L3
2L1
Feed line connection 1~ 1~
1GRD
2GRD
see page 12
3-phase power supply for the compressor additional 115V, 1-ph, 60Hz power supply
ev Y
-M30 -M31
according to the machine nameplate for the refrigeration dryer
Function: input voltage input voltage compressor motor vent motor condensate drain
Group of function: compressor refrigeration dryer power unit refrigeration dryer refrigeration dryer
=
c Date 13.03.2019
is wiring diagram
b Drawn Taubmann +
a Released Büchner
D Change Date Name power supply, refrigeration dryer SC2 MCSIO SSXC-U3107.00 12 Sht.
io
9_6917 43 USE
n
1 2 3 4 5 6 7 8
1L1
/1.8
1L2
9_6917 43 USE
/1.8
1L3
/1.8
GRD -X01 1GRD

/1.8
12AWG 12AWG
PR
13
10AWG black 10AWG black

13.3
black 600V 90°C black 600V 90°C

Su
600V 90°C 600V 90°C
Annex
1
3
5
1
3
5
1
3
5
1
3
5
1
3
5
1
3
5
-Q1 -Q2 -Q3 ATTENTION !!! -Q1 -Q2 -Q3

/3.3 component -B25
EL
/3.2 /3.4
bj
2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
2
4
6
ATTENTION !!!
component -B25 14AWG Adjust the setting 14AWG
black depending on black
Electrical Diagram

1
1
3
5
3
5
97
95
97
95
Adjust the setting -B25 600V 90°C the mains voltage -B25 600V 90°C
ec
depending on
IM
**** Use the ****
2
4
6
2
4
6

the mains voltage
98
98
96
overload relay
with suitable
/3.3 96
Use the
-W19.1 setting range -W19.1
overload relay
**** ****
with suitable -W19.2
I
GRD
W3 V4
setting range ****
tt
ATTENTION !!! W1 V2
GRD
W3 V4 component -M1,-X1
ATTENTION !!! V3 U4
component -M1 W1 V2
Check the correct M
V1 U2
V3 U4 connection of 3~
Check the correct
o NA
M the motor according U3 W4
connection of V1 U2
3~ to the mains voltage
the motor according U1 -M1 W2
U3 W4
to the mains voltage ****
-W19.2
U1 -M1 W2
R R
****
**** -X1 3
2
diagram 1 1
208V/230V diagram 2
ev Y
460V
**** performance-related components,
see: electrical component parts list
Function: compressor motor

Group of function:
is
power unit
c Date 13.03.2019 wiring diagram =
b Drawn Taubmann +
a Released Büchner
power unit SC2 MCSIO SSXC-U3107.00
D Change Date Name 12 Sht.
io
109
n
110
1 2 3 4 5 6 7 8
95
21
-B25 -Q1
/2.2 2
96
22
7
13
X7 X7
10
X7
11
13.3
PR
-K20 -K20 -K20
DI_PA DI 1.01 DI 1.02
Su
/7.2 /7.2 /7.2
overload relay answerback signal

compressor motor main contactor
Annex
main contactor wye contactor delta contactor

EL
vent motor Oil cooler
bj
-K20 DOR 1.00 -K20 DOR 1.01 -K20 DOR 1.02 -K20 DOR 1.04
Electrical Diagram

/7.2 COM /7.2 COM /7.2 COM /7.2
11
10
9
2
1
X10 X10 X10 X10

ec IM
P+ /5.7
13
13
21
21
-Q1 -Q3 -Q2 -Q3
2 3 4 3
I
14
14
22
22
tt
A1
A1
A1
A1
-Q1 -Q3 -Q2 -Q4
A2
A2
A2
A2
o NA
-X11 01 L02
/5.1
1 2 1 2 1 2 1 2
/2.2 /2.4 /2.3 /5.5
3 4 3 4 3 4 3 4
R R
/2.2 /2.4 /2.3
5 6 5 6 5 6 5 6
/2.2 /2.4 /2.3
13 14 13 14 13 14 13 14
2 3
21 22 21 22 21 22
4 4 3
31 32
/9.4
43 44
/9.5
ev Y
Function:
Group of function: wye-delta changeover
=
c Date 13.03.2019
is wiring diagram
b Drawn Taubmann +
a Released Büchner
control SC2 MCSIO SSXC-U3107.00
io
9_6917 43 USE
n
1 2 3 4 5 6 7 8
-X31 7 2L+
9_6917 43 USE
/6.4
3
-W179
2
-3X31
1
-W172
-B30
P
PR
13
13.3
>21 bar
Su
2
-W172 safety air pressure switch
(Pressure limiter) Refrigerant compressor
3
-3X31 -K20 -K20
DI 1.03 DOR 1.03
/7.2 /7.2
4
-W179
Annex
12
4
5
X7 X10
bj EL
8
-X31
10
-X31
Electrical Diagram

ec IM

tt I
A1
-Q30
o NA
A2
2L-
/6.4
R R
1 2
/1.5
3 4
5 6
/1.5
13 14
ev Y
Function:
Group of function:
is
b Drawn Taubmann +
a Released Büchner
air dryer control SC2 MCSIO SSXC-U3107.00
io
111
n
112
1 2 3 4 5 6 7 8
11L1 -X11 1 -X11 2 -X11 2 L01

/1.8 /6.1
11L2
/1.8
14AWG 14AWG 14AWG
black black black
11
21
-S1
600V 90°C 600V 90°C 600V 90°C
-X11 GRD2
1
3
5
22
12
-1FU -2FU -3FU EMERGENCY STOP
2
1,5A 1,5A 1,5A -Q4
2
4
6
Class CC Class CC Class CC /3.5
13
1
3
13.3
-X11
PR
8
9
14AWG black X7
14AWG
Su
600V 90°C 14AWG
black -K20 DI_PA DI
black
14AWG green/yellow 600V 90°C DI 1.00
600V 90°C /7.2
600V 90°C
4
-T11 -X11 EMERGENCY STOP
Annex
-X11 GRD1
-K20 DOR COM

GNYE
EL
BU
bj
ATTENTION !!! component -T11 250VA BN COM
/7.2
BK
Electrical Diagram
8
7
14AWG X10

Check the correct connection
5
grey model-specific -X11
U1
Z
U2
GRD
of the transformer according
600V 90°C electrical diagram

to the mains voltage
ec IM
see page 11 -C4
M
03
-X11
1~ -K20-X10:1
/3.6 P+
16AWG green/yellow
600V 90°C -M4
0,73A
I
GRD1
-X11
tt
L02 -X11 02 02 L02
/3.6 /6.1
o NA
R R
ev Y
Function: 115V/1ph/60Hz EMERGENCY STOP
Group of function: control voltage tapping safety chain
=
c Date 13.03.2019
is wiring diagram
b Drawn Taubmann +
a Released Büchner
control voltage tapping SC2 MCSIO SSXC-U3107.00
io
9_6917 43 USE
n
1 2 3 4 5 6 7 8
L01 -X11 1 L01
9_6917 43 USE
/5.8
L02 01 L02
/5.8
-K20
MCS
1x4mm² X5
PR
1x2,5mm²
SD card
13
green/yellow
13.3
green/yellow
500V 70°C
Su
-X11 GRD2 500V 70°C X6
P24
M24
Ethernet RS485-FC
1
2
X7
control cabinet door X1 X3
/7.2
Annex
bj EL
Electrical Diagram

ec IM

-T21
1)
100- + 2L+
/4.4
L1
240V~
24V=
+
-
tt I
N - 2L-
/4.5
2,5A -
short circuit proof
1x1,5mm²
o NA
green/yellow
500V 70°C
GRD2
-X11
R R
ev Y
1) Reset: Switch off L1 for 3 minutes
Function: 24V DC
Group of function:
is
control voltage
b Drawn Taubmann +
a Released Büchner
power supply unit SC2 MCSIO SSXC-U3107.00
io
113
n
c
a
b
Function:
D Change
1
Group of function:
Date
Name
Date
Drawn
Released
2
-K20
Büchner
Taubmann
13.03.2019
Su
1
P24 24V /6.4
2
M24 0V /6.4
3
IOM
DI_PA
4
DI_PA
bj
5
DI_PA
6
DI_PA
3
7
DI_PA /3.2
X7
8
DI_PA /5.7
9
DI 1.00 /5.7
ec
10
DI 1.01 /3.3
11
DI 1.02 /3.4
PR
12
DI 1.03 /4.3
13
DI 1.04
tt
14
DI 1.05
1
4
DI_PA /8.5
2
DI 1.06 /8.5
3
DI_PA
EL
4
DI 1.07
5
DOT 1.00 /8.7
X8
6
M /8.7
7
DOT 1.00 /8.6
8 /8.6
M
IM
9
DOT 1.01
5
10
I
M
/3.5 1 1 /8.2
DOR COM AII_PA
wiring diagram
/3.5 2 2 /8.2
DOR 1.04 AII 1.00
3 3 /8.2
FE
IO-module configuration
/4.4 4 4
DOR COM GND
/4.4 5 5
DOR 1.03 AII_PA
is
6 6
AII 1.01
X10
o NA
7 7
DOR COM FE
6
X9
8 8 /8.3
/5.7 DOR COM AIR 1.00
/3.4 9 9 /8.3
io
DOR 1.02 AIR 1.00
/3.3 10 10 /8.3
R R
DOR 1.01 FE
/3.2 11 11
DOR 1.00 AIR 1.01
12
n
AIR 1.01
13
FE
ev Y
SC2 MCSIO
7
+
=
SSXC-U3107.00
8
page
12 Sht.
7
Electrical Diagram 13.3
Annex 13
1 2 3 4 5 6 7 8
9_6917 43 USE
-B1 -B40
P
1
-B2
4...20mA P
2
Pt100
+ - >1,0 bar
1
2
1
4
PR
13
13.3
1
2
BN
BK
1
2
-W115 -W117 -W104
Su
2x0,5mm² 2x0,34mm² 2x0,5mm²
500V 70°C 250V 80°C 500V 70°C
Annex
1
2
3
8
9
1
2
X9 X9 X8
10
bj EL
-K20 AII_PA AII FE -K20 AIR_A AIR_B FE -K20 DI_PA DI
/7.2 AII 1.00 /7.2 AIR 1.00 /7.2 DI 1.06

Electrical Diagram

Network pressure airend discharge temperature direction of rotation
ec IM

bypass valve
-K20 DOT 1.00 -K20 DOT 1.00
/7.2 DOT M /7.2 DOT M
7
5
8
6
X8 X8
tt I
24VDC / max. 0,1A
1
2
-W113 For service purposes only.

2x0,5mm²
o NA
500V 70°C
1(+)
2(-)
R R
1
2
-K1
ev Y
Function:
Group of function:
is
b Drawn Taubmann +
a Released Büchner
sensors/actuators SC2 MCSIO SSXC-U3107.00
io
115
n
116
1 2 3 4 5 6 7 8
13
13.3
PR
volt-free contacts
Su
User's connection
Annex
bj EL
31
43
-Q1 -Q1
/3.2 /3.2
Electrical Diagram

32
44

ec
16
17
15
IM
-X11 -X11 -X11
max. 250V AC/24V DC, 3A

tt I
o NA
For Field Wiring:
R R
Use Copper Conductors Only!
Connect Control Device Only!
all non-designated conductors,

16AWG orange
ev Y
Function: compressor motor running
Group of function: volt-free contacts
=
c Date 13.03.2019
is wiring diagram
b Drawn Taubmann +
a Released Büchner
volt-free contacts SC2 MCSIO SSXC-U3107.00
io
9_6917 43 USE
n
1 2 3 4 5 6 7 8
9_6917 43 USE
Inputs/outputs for use by others ** pre-allocated
*** available for use
example connections
For Field Wiring:
digital output, User's connection
Use Copper Conductors Only!
24V DC/0,3A
Connect Control Device Only!
max. cable length 30m
PR
13
13.3
control ON **
Su
-K20 DOT 1.01
DOT M
9
10
X8
Annex
bj EL
possible connections for AII 1.01
Electrical Diagram

4-wire connection
ec IM
2-wire connection

L+ L-
?
?
4...20mA 4...20mA
tt I
o NA - out + -
Pt100
4
5
3
4
4
5
6
7
4
5
6
7
X7 X7 X8 X9 X9
13
14
11
12
13
R R
-K20 DI_PA DI -K20 DI_PA DI -K20 DI_PA DI -K20 GND AII_PA AII FE -K20 GND AII_PA AII FE -K20 AIR_A AIR_B FE
DI 1.04 DI 1.05 DI 1.07 AII 1.01 AII 1.01 AIR 1.01

Remote ON/OFF ** *** *** 4-20mA, 18V DC
4-20mA
Ri = 200Ω Ri = 200Ω
ev Y
digital inputs, User's connection
18V DC/7mA analog inputs, User's connection
max. cable length 100m max. cable length 30m
is
b Drawn Taubmann +
a Released Büchner
inputs/outputs SC2 MCSIO SSXC-U3107.00
io
117
n
118
1 2 3 4 5 6 7 8
status on delivery ATTENTION !!!

The transformer is
1L1
1L2
-1FU
-2FU
not connected (nc) correctly
on the primary side.
13
0
13.3
nc
Therefore the compressor
PR
208V
230V
460V
-T11 is non-functional at the
Su
-X11 GRD2 status on delivery !
Connect the line L2 to the
Annex
0
115V
correct transformer terminal
according to the mains voltage.
bj EL
L02
-3FU
Electrical Diagram

ec IM
diagram 1 diagram 2 diagram 3
208V
tt
230V
I 460V
1L1
1L2
1L1
1L2
1L1
1L2
-1FU
-2FU
-1FU
-2FU
-1FU
-2FU
o NA
0
0
0
nc
nc
nc
208V
230V
460V
208V
230V
460V
208V
230V
460V
-T11 -T11 -T11

-X11 GRD2 -X11 GRD2 -X11 GRD2
R R
0
115V
0
115V
0
115V
ev Y
L02
-3FU
L02
-3FU
L02
-3FU
c Date 13.03.2019
is wiring diagram =
b Drawn Taubmann +
a Released Büchner
transformer diagrams SC2 MCSIO SSXC-U3107.00
io
9_6917 43 USE
n
1 2 3 4 5 6 7 8
fig. 1: Handling: Control line terminal fig. 10: Feed line connection
9_6917 43 USE
PR
13
13.3
Su
Annex
bj EL
Electrical Diagram

ec IM

fig. 2: Handling: Supply terminal I
tt
o NA
R R
ev Y
is
b Drawn Taubmann +
a Released Büchner
Handling: Terminals/Feed line connection SC2 MCSIO SSXC-U3107.00
io
119
n
120
cable-no.
-W19.2 connection 460V
-W19.1 ****
13
13.3
PR
1
3
3
5
1
V3
U3
W3
connection
GRD
Su
GRD1
inside
destination
name of device
-1FU
-Q1
-2FU
-Q1
-X11
-M1
-M1
-M1
-M1
control panel
-Q1
Annex
location
/1.2
/1.2
/1.3
/2.3
/2.6
/2.6
/2.6
/1.3
/1.2
bj EL
jumper wire
Electrical Diagram

terminal legend
total 9 terminals
total 3 terminals
terminal strip

terminal strip: -X1
ec
link
IM
terminal strip: -X01

terminal-no.
1U
1V
1V
1W
1GRD
1GRD
1
2
3
1GRD
1U
1GRD
V2
U2
W2
connection
I
external
destination
tt
name of device
-supply
-supply
unit frame
-M1
-M1
-M1
-supply
-supply
-W19.2 connection 460V
-s.b.c. *
o NA
cable-no.
R R
ev Y
* supply line cross-section
see operating manual
**** performance-related components,
see: electrical component parts list
s.b.c. = supplied by customer
c Date 13.03.2019
isterminal connection =
b Drawn Taubmann +
a Released Büchner
H Change Date Name terminal strip -X01,-X1 SC2 MCSIO KSXC-U3107.00 2 Sht.
io
9_6917 43 USE
n
c
a
b
destination destination
cable-no. terminal strip cable-no.
inside external
H Change
link
location
connection
connection
jumper wire
terminal-no.
Date
name of device
name of device
terminal legend
Name
-W80 2x18AWG 600V 90°C
-W29 4G20AWG 600V 90°C
-W172 2x18AWG 600V 90°C
-W179 5G14AWG 600V 90°C

-W170 3G14AWG 600V 90°C
-W171 3G18AWG 600V 90°C
Date
Drawn
Released

total 16 terminals
GN
GN
-3X31 GRD GRD2 /5.5 -M4 GRD

YE
YE
Büchner
Taubmann
13.03.2019
Su
control cabinet door GRD2 /6.3 -T21 -

-T11 GRD GRD1 /5.2 .
-X01 1GRD GRD1 /1.3
-3FU 5 1 /5.4 -T21 L1
-Q4 A2 01 /3.6 -T21 N
bj
2) class 2 control circuit
-Q4 2 2 /5.7 -S1 11

BL
-C4 02 /5.5 -M4 U2

1) compressor motor running
-K20-X10 8 3 /5.7 -S1 12

volt-free contacts, User's connection
-T11 0 03 /5.2
-Q4 1 4 /5.5 -M4 U1
BU BN
-C4 5 /5.6 -M4 Z

ec
-Q1 43 15 /9.4 1)
-Q1 32 16 /9.4 1)
-Q1 44 17 /9.5 1)
PR
18
tt

total 2 terminals
-P34 X1 1 /1.6 -Q30 2
-P34 X2 2 /1.6 -Q30 6
EL

total 4 terminals
2) -3X31 2 7 /4.2 -T21 +
3 4 2) -3X31 3 8 /4.2 -K20-X7 12
9
10 /4.2 -K20-X10 4
IM
terminal strip: -3X31
I
total 9 terminals
2) -X31 8 3 /4.2 -B30 2)
4 3
2 1
2) -X31 7 2 /4.2 -B30 2)
1
1
-M30 L1 1 /1.5 -M31 L1
terminal connection
1
1
-Q30 1 1 /1.7 -K34 L/+
2
2
-M30 L2 N /1.5 -M31 L2
2
2
-Q30 5 N /1.7 -K34 N/-
is
GN
' GRD /1.7 -M31 GRD

YE
terminal strip -X11,-X30,-X31,-3X31

GN
-M30 GRD GRD /1.6
YE
o NA
GN
-X11 GRD2 GRD /1.7 base plate air dryer
YE
io
R R
n
ev Y
SC2 MCSIO
GNYE = green/yellow
+
=
KSXC-U3107.00
page
2
2 Sht.
Electrical Diagram 13.3
Annex 13
122
1 2 3 4 5 6 7 8
-C4
13
13.3
PR
-X11
-X30
Su
-X31
-Q30
Annex
-Q4
-1FU
-2FU
EL
-3FU
bj
-4FU
-X02
Electrical Diagram

-B25
-X1

ec IM
-T21
I -T11
tt
-X01
-Q1 -Q2 -Q3
o NA
-B25
R R
ev Y
The components are performance-related
and not shown to scale.
c Date 13.03.2019
is lay-out =
b Drawn Taubmann +
a Released Büchner
Switchboard SC2 MCSIO ASXC-U3107.00
I Change Date Name 1 Sht.
io
9_6917 43 USE
n

Airtower With SC2 9 - 6917 - 43USE

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Operator Manual

AIRTOWER 3C–7.5C Tri-Voltage

1 Regarding this Document

2.13 Sound emission ................................................................................................................ 10

3 Safety and Responsibility

3.3 Improper use .................................................................................................................... 14

3.4.1 Observe statutory and universally accepted regulations .................................... 14

3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 15

3.5.4 Danger Areas ...................................................................................................... 20

3.8 Safety signs ...................................................................................................................... 21

Operator Manual Screw Compressor

4.2 Machine overview ............................................................................................................ 27

6.4 Connecting the condensate drain .................................................................................... 38

6.7.2 Connect power to the machine ........................................................................... 42

7.1 Ensuring safety ................................................................................................................ 44

7.2 Instructions to be observed before commissioning .......................................................... 45

7.4 Setting the overload protection relay ................................................................................ 46

8.1.2 Switching off ....................................................................................................... 49

Operator Manual Screw Compressor

10.14 Changing the cooling oil ................................................................................................... 71

10.17.2 Maintaining the condensate drain ....................................................................... 78

11.1 Note the nameplate .......................................................................................................... 83

11.2 Ordering spare parts and operating fluids/materials ........................................................ 83

11.4 Replacement parts for service and repair ........................................................................ 84

12.2 Packing ............................................................................................................................ 89

12.4.1 Safety .................................................................................................................. 90

Operator Manual Screw Compressor

Operator Manual Screw Compressor

Fig. 1 Maximum relative humidity of inlet air ........................................................................................ 6

Fig. 25 Compressor: Checking the safety relief valve ............................................................................ 64

Fig. 30 Replenishing cooling oil .............................................................................................................. 69

Fig. 34 Changing the oil separator cartridge .......................................................................................... 76

Fig. 36 Checking the condensate drain .................................................................................................. 78

Fig. 38 Air receiver maintenance ............................................................................................................ 80

Operator Manual Screw Compressor

Operator Manual Screw Compressor

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

Tab. 25 Safety Signs ............................................................................................................................... 22

Tab. 30 Condensate line ......................................................................................................................... 39

Tab. 34 Overload protection cutout settings. ........................................................................................... 42

Tab. 36 Installation conditions checklist .................................................................................................. 45

Tab. 38 Remote control center identification ........................................................................................... 51

Tab. 43 Oil change intervals lubricants ................................................................................................... 59

Tab. 46 Logged maintenance tasks ........................................................................................................ 82

Operator Manual Screw Compressor

Operator Manual Screw Compressor

1 Regarding this Document

Missing documents can be requested from KAESER.

1.4 Symbols and labels

➤ Please note the symbols and labels used in this document.

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

Operator Manual Screw Compressor

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

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!

Potential effects when ignoring the warning are indicated here.

➤ Carefully read and fully comply with warnings against damages.

1.4.3 Other alerts and their symbols