Page 1 Operating Manual Rotary screw compressor 901848 21 E Manufacturer: KAESER KOMPRESSOREN SE 96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130 http://www.kaeser.com...
Page 2 Original instructions /KKW/SSK 2.21 en SBA-SCHRAUBEN-SC2IO /KKW/SSC 2.08 20180629 105600...
Page 3: Table Of Contents
Contents Regarding this document Using this document ......................Further documents ......................Copyright .......................... Symbols and labels ......................1.4.1 Warnings ......................1.4.2 Potential damage warnings ................1.4.3 Other alert notes and their symbols ..............Technical Specifications Nameplate ........................Options ..........................Mass ..........................Temperature ........................
Page 4 Contents Operating panel SIGMA CONTROL 2 ................Operating modes and control modes ................4.4.1 Machine operating modes .................. 4.4.2 Control modes ....................Options ..........................4.5.1 SIGMA CONTROL 2 controller: Connection to control technology ....4.5.2 Machine mountings ..................... 4.5.3 Prepared for external heat recovery ..............Installation and Operating Conditions Ensuring safety ........................
Page 5 10.19 Documenting maintenance and service work ..............Spares, Operating Materials, Service 11.1 Note the nameplate ......................11.2 Ordering consumable parts and operating fluids/materials ..........11.3 KAESER AIR SERVICE ....................11.4 Replacement parts for service and repair ................ Decommissioning, Storage and Transport 12.1 De-commissioning ......................
Page 6 Contents Operating Manual Rotary screw compressor 901848 21 E...
Page 7 List of Illustrations Fig. 1 Maximum relative humidity of intake air ..................Fig. 2 Location of safety signs ......................Fig. 3 Enclosure overview ........................Fig. 4 Machine layout ........................... Fig. 5 Keys – overview ......................... Fig. 6 Indicators – overview ........................Fig.
Page 8 List of Illustrations Operating Manual Rotary screw compressor 901848 21 E...
Page 9 List of Tables Tab. 1 Danger levels and their definition (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 Nameplate ..........................Tab. 4 Options ............................Tab. 5 Mass ............................Tab. 6 Temperature ..........................Tab.
Page 10 List of Tables Operating Manual Rotary screw compressor viii 901848 21 E...
Page 11: Regarding This Document Using This Document
➤ Make sure you provide the data from the nameplate when ordering documents. Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully suppor‐ ted. Symbols and labels ➤...
Page 12: Potential Damage Warnings
Regarding this document Symbols and labels Some warning notes may precede a chapter. They apply to the entire chapter including all sub-sec‐ tions. Example: DANGER The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. The word "DANGER"...
Page 13 Regarding this document Symbols and labels 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 ➤...
Page 14: Technical Specifications Nameplate
Technical Specifications Nameplate 2 Technical Specifications Nameplate The model designation and important technical information are given on the machine's nameplate. The nameplate is located on the outside of the machine: ■ above the cooler, or ■ on the rear of the machine. ➤...
Page 15: Mass
Technical Specifications Mass Mass The values shown are maximum values. Actual mass of individual machines are dependent on equipment fitted. SK 22 SK 25 — Mass [kg] — Tab. 5 Mass Temperature SK 22 SK 25 — Minimum cut-in tempera‐ —...
Page 16: Ventilation
Technical Specifications Ventilation Fig. 1 Maximum relative humidity of intake air Intake air temperature [°C] Maximum relative humidity of intake air [%] Ventilation The values given are minimum guide values. Mains frequency: 50 Hz SK 22 SK 25 — Inlet aperture see fig‐...
Page 17: Flow Rate (Constant Delivery Volume Relative To Intake Conditions)
Technical Specifications Flow rate (constant delivery volume relative to intake conditions) Pressure relief valve activating pressure at 50 Hz [bar]: Maximum working over‐ SK 22 SK 25 — pressure [bar] — 11.0 — 15.0 —* * China: 15.9 Tab. 10 Pressure relief valve activating pressure (50Hz) Pressure relief valve activating pressure at 60 Hz [bar]: Maximum working over‐...
Page 18: Cooling Oil Recommendation
Technical Specifications Cooling oil recommendation Cooling oil recommendation A sticker showing the type of oil used is located near the oil separator tank filler. For information on ordering cooling oil, please see chapter 11. Cooling oils for general applications SIGMA FLUID S-460 S-570 Description Mineral oil...
Page 19: Cooling Oil Charge
Technical Specifications 2.10 Cooling oil charge SIGMA FLUID FG-460 FG-680 Viscosity at 8.0 mm /s (ASTM D445) 10.5 mm /s (ASTM D445) 100 °C Flash point 246 °C (ASTM D92) 238 °C (ASTM D92) Density at 0.842 g/cm (ASTM D1298) 0.854 g/cm (ASTM D1298) 15 °C...
Page 20: Motors And Power
Technical Specifications 2.11 Motors and power Option W1 Heat recovery The additional volume corresponds to the oil volume of the heat exchanger and the connecting lines: SK 22 SK 25 — Additional charge vol‐ ume [l]* * Enter the volume required by your heat recovery system. Tab.
Page 21: Electrical Connection
Technical Specifications 2.13 Electrical connection Mains frequency SK 22 SK 25 — 60 Hz — Noise pressure level in operation at maximum working gauge pressure as per ISO 2151 and the basic standard ISO 9614-2, uncertainty: ±3 dB(A) Tab. 22 Noise emission [dB(A)] 2.13 Electrical connection...
Page 22: Mains Frequency: 50 Hz
Technical Specifications 2.14 Power supply specifications ➤ For other application conditions, check and determine the supply diameters according to DIN VDE 0100 and DIN VDE 0298-4:2013-06 or the local energy provider. Other conditions would include, for example: ■ Higher ambient temperature ■...
Page 23: Mains Frequency: 60 Hz
Technical Specifications 2.14 Power supply specifications The machines listed in the table are intended for operation with a public power supply with a net‐ work impedance at the transfer point (house connection) of maximum Z [Ohm]. max. The operator must ensure that the machines are only connected to a network that meets these re‐ quirements.
Page 24: Available Heat Capacity
Technical Specifications 2.15 Available heat capacity Rated voltage: 460V / 3 / 60Hz SK 22 SK 25 — Backup fuse [A] — — Supply cable [mm Current drawn [A] — Tab. 30 Supply details 460V / 3 / 60Hz 2.15 Option W1 Available heat capacity The quality of the heat transfer medium and its required flow rate depend on the type of heat...
Page 25: Safety And Responsibility Basic Instructions
Safety and Responsibility Basic instructions 3 Safety and Responsibility 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, ■...
Page 26: Determining Personnel
Safety and Responsibility User's responsibilities ➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐ nance of the machine. 3.4.2 Determining personnel Suitable personnel are experts who, by virtue of their training, knowledge and experience as well as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐ sible dangers involved.
Page 27: Dangers
Inspection Inspection interval Inspecting authority Installation and equip‐ Before commissioning Competent person ment inspection (e. g. KAESER SERVICE technician) Internal inspection Every 5 years after installation or Competent person the last inspection (e. g. KAESER SERVICE technician) Strength test Every 10 years after installation or...
Page 28 Safety and Responsibility Dangers ➤ De-pressurise all pressurised components and enclosures. ➤ Do not carry out welding, heat treatment or mechanical modifications on pressurised compo‐ nents (e.g. pipes and vessels) as this influences the component's resistance to pressure. The safety of the machine is then no longer ensured. Compressed air quality The composition of the compressed air must be suitable for the actual application in order to pre‐...
Page 29: Safe Machine Operation
Unsuitable spare parts compromise the safety of the machine. ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER replacement parts on pressure bearing parts. Conversion or modification of the machine Modifications, additions to and conversions of the machine or the controller can result in unpredict‐...
Page 30 Safety and Responsibility Dangers ■ Safety boots ■ Eye protection ■ Ear protection Transport The mass and size of the machine require safety measures during its transport to prevent acci‐ dents. ➤ Use suitable lifting gear that conforms to local safety regulations. ➤...
Page 31: Organisational Measures
➤ Do not open the cabinet while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Carry out regular inspections: for visible damages,...
Page 32: Safety Devices
Safety and Responsibility Safety devices Activity Danger area Authorised personnel Transport Within a 3 m radius of the machine. Installation personnel for transport preparation. No personnel during transport. Beneath the lifted machine. No personnel! Installation Within the machine. Installation personnel Within 1 m radius of the machine and its sup‐...
Page 33: Safety Signs
Safety and Responsibility Safety signs 1. The components of the safety functions must be replaced by KAESER SERVICE after a work‐ ing life of 20 years. 2. Have the KAESER SERVICE check the reliability of the safety functions. Safety signs The figure shows the position of the safety signs on the machine.
Page 34: Emergency Situations
Safety and Responsibility Emergency situations Position Sign Meaning Personal injury or damage to the machine by incorrect operation! ➤ Read and understand the service manual and all safety signs before switch‐ ing on this machine. Risk of injury caused by an automatic machine start! ➤...
Page 35: Warranty
■ incorrect maintenance, ■ incorrect repair. Correct maintenance and repair includes the use of genuine KAESER spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.11 Environment protection The operation of this machine may cause dangers for the environment.
Page 36: Design And Function
Design and Function Enclosure 4 Design and Function Enclosure Fig. 3 Enclosure overview Control cabinet door Sight glass: Oil level indicator Latch Sight glass: V-belt tension Panel (removable) When closed, the enclosure serves various functions: ■ Sound insulation ■ Protection against contact with components ■...
Page 37: Machine Function
Design and Function Machine function Machine function Fig. 4 Machine layout Inlet valve Control cabinet Minimum pressure/check valve Oil separator tank Compressor motor Air filter Oil filter Oil/air cooler Airend Ambient air is cleaned as it is drawn in through the filter The air is then compressed in the airend The airend is driven by an electric motor Cooling oil is injected into the airend.
Page 38: Floating Relay Contacts
Design and Function Operating panel SIGMA CONTROL 2 ■ Pressure relief valve: The pressure relief valve protects the system against excessive pressure. It is factory set. ■ Resistance thermometer: Monitoring the airend discharge temperature protects the compressed air system from imper‐ missible temperature rises.
Page 39: Fig. 6 Indicators - Overview
Design and Function Operating panel SIGMA CONTROL 2 Position Name Function «Accept» Jumps to the selected menu option. Exits the edit mode and saves. «Down» Scrolls down the menu options. Reduces a parameter value. «Right» Jumps to the right. Moves the cursor position to the next right field. «Left»...
Page 40: Fig. 7 Rfid Reader
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐ vate the communication between transponder and SIGMA CONTROL 2. A suitable transponder is the KAESER RFID Equipment Card. Two of them have been provided with the machine.
Page 41: Operating Modes And Control Modes
Design and Function Operating modes and control modes Position Name Function RFID RFID reader for the communication with a suitable RFID transponder. Tab. 38 RFID reader Further information More information about the use of RFID technology is provided in the SIGMA CONTROL 2 operat‐ ing manual.
Page 42: Control Modes
Design and Function Operating modes and control modes 4.4.2 Control modes Using the selected control mode, the controller switches the machine between its various opera‐ tional states in order to maintain the gauge working pressure between the set minimum and maxi‐ mum values, regardless of the drawn compressed air volume.
Page 43: Options
Design and Function Options VARIO idling The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the time is automatically lengthened or shortened to compensate for higher or lower machine starting frequencies. Option C1 MODULATING control The MODULATING control is an additional mechanical regulation.
Page 44: Prepared For External Heat Recovery
Working elements are marked with their opening temperature [°C]. If the cooling oil temperature is too low, condensate can form and damage the machine. ➤ Consult KAESER Service on components and layout to ensure proper functioning of the cooling and heat recovery systems.
Page 45: Installation And Operating Conditions
The distances quoted are recommended distances and ensure unhindered access to all ma‐ chine parts. ➤ Please consult KAESER if they cannot be kept to. Precondition The floor must be level, firm and capable of bearing the mass of the machine.
Page 46: Ensuring The Machine Room Ventilation
It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐ tions. ➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of the machine room. 1. Ensure that the flow volume of fresh air is at least the same as the volume taken by the ma‐...
Page 47: Exhaust Duct Design
The machine can only overcome the air resistance at the cooling air inlet and exhaust determined by the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐ ing. ➤ Consult the KAESER SERVICE representative before deciding on: ■ Design of the exhaust air ducting ■...
Page 48: Installation
Installation Ensuring safety 6 Installation Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Page 49: Reporting Transport Damage
➤ Install only corrosion-resistant pipes. ➤ Use fluoroelastomers as sealing material for seals. ➤ Note the electro-chemical voltage sequence. ➤ Consult with KAESER for suitable materials for the compressed air network. Precondition The compressed air system is vented completely to atmospheric pressure.
Page 50: Connecting The Machine With The Power Supply
Safety monitoring of the machine's internal pressure is unaffected. Your authorized KAESER SERVICE technician 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.
Page 51: Options
An unsuitable heat exchanger or incorrect installation may influence the cooling oil circuit within the compressor. Damage to the machine will follow. ➤ Consult KAESER on a suitable heat exchanger and have KAESER SERVICE do the installa‐ tion. Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connec‐...
Page 52: Initial Start-Up Ensuring Safety
Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Here you will find instructions for a safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Page 53: Instructions To Be Observed Before Commissioning
➤ Change the cooling oil. ➤ Manually fill the airend with cooling oil. 36 months ➤ Have the overall technical condition checked by an authorised KAESER SERVICE technician. Tab. 41 Re-commissioning after storage/standstill Checking installation and operating conditions ➤ Check and confirm all the items in the checklist before commissioning the machine.
Page 54: Setting The Overload Protection Cut-Out
➤ Check the settings of the overload relay. The overload relay shuts the machine down despite being correctly set? ➤ Contact the authorised KAESER SERVICE. Pouring cooling oil into the airend Before starting the compressor for the very first time and before re-starting after a shutdown period of more than 3 months it is necessary to manually add a quantity of cooling oil into the airend.
Page 55: Activating And Deactivating The Modulating Control
Control valve (proportional control) Shut-off valve ➤ Open or close the shut-off valve, depending on the required control mode. The regulating valve is factory set. Consult with KAESER SERVICE before changing. Starting the machine for the first time Precondition No personnel are working on the machine.
Page 56: Setting The Set Point Pressure
Initial Start-up Setting the set point pressure 1. Open the user's shut-off valve to the air network. 2. Switch on the power supply disconnecting device. Control voltage LED is lit continuously. After the controller has carried out a self-test, the green 3.
Page 57: Setting The Display Language
The controller displays an alarm message. 2. Close the panel and acknowledge the alarm. The machine does not shut down? ➤ Have the interlock switch checked by an authorised KAESER SERVICE Technician. 7.10 Setting the display language The controller can display text messages in several languages.
Page 58: Operation
Operation Switching on and off 8 Operation 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. Fig. 14 Switching on and off ON LED «LOAD/IDLE»...
Page 59: Switching Off In An Emergency And Switching On Again
Operation Switching off in an emergency and switching on again Voltage applied to controller LED extinguishes. The machine is switched off and disconnected Result from the mains supply. In rare cases, you may want to shut down the machine immediately and cannot wait until the automatic shut-down process is finished.
Page 60: Using The Timer For Switching On And Off
Operation Using the timer for switching on and off Fig. 16 Using the remote control for switching on and off «Remote control» key Remote control LED 1. Attach an easily seen notice to the machine that warns of remote operation. Remote control: Risk of injury caused by unexpected starting! ➤...
Page 61: Interpreting Operation Messages
Operation Interpreting operation messages Fig. 17 Using the timer for switching on and off «Timer» key Timer LED 1. Attach an easily seen notice warning of time-controlled operation: Time 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.
Page 62: Fig. 18 Acknowledging Messages
Operation Acknowledging alarm and warning messages Fig. 18 Acknowledging messages Warning LED (yellow) Fault LED (red) «Acknowledge» key Alarm message Fault LED flashes red. An alarm shuts the machine down automatically. The The system displays the appropriate message. Precondition The fault has been rectified ➤...
Page 63: Fault Recognition And Rectification
1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorised KAESER SERVICE representative. Further information See the operating manual of SIGMA CONTROL 2 for details regarding the various messages.
Page 64: Tab. 47 Other Faults And Remedies
Oil cooler leaking. Call KAESER SERVICE. Leaking pipe joints. Tighten pipe joints. Replace seals. Cooling oil consumption too Unsuitable oil is being used. Change to SIGMA FLUID cool‐...
Page 65: 10.1 Maintenance
Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Page 66: Following The Maintenance Plan
Details of dangers and their avoidance are found in chapter 3.5. 10.2 Following the maintenance plan 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work at shorter intervals. Adverse conditions are, e.g.: ■...
Page 67: Cooling Oil Change Interval
Maintenance 10.2 Following the maintenance plan ➤ Take note of the controller's service messages and carry out tasks punctually, taking ambient and operating conditions into account. Interval Maintenance task see chapter Weekly Check the cooling oil level. 10.13 Cooler: 10.3 Check the filter mat Control cabinet: 10.4...
Page 68: Regular Service Tasks
Maintenance 10.2 Following the maintenance plan KAESER SERVICE will support you in determining appropriate intervals and provide informa‐ tion on the possibilities of oil analysis. ➤ Observe national regulations regarding the use of cooling oil in oil-injected rotary screw com‐...
Page 69: Cooler: Cleaning Or Renewing The Filter Mats
Maintenance 10.3 Cooler: Cleaning or Renewing the Filter Mats 10.3 Cooler: Cleaning or Renewing the Filter Mats The filter mats help to keep the cooler clean. If the filter mats are clogged, adequate cooling of the components is no longer ensured. Material Filter mats: Warm water and household detergent...
Page 70: Cooler Maintenance
Clogged coolers are indicative of unfavourable ambient conditions. Such ambient conditions clog the cooling air ducts in the machine's interior and the motors resulting in increased wear and tear. ➤ Have the authorised KAESER SERVICE technician clean the cooling air ducts. Material Brush and vacuum cleaner...
Page 71: Maintaining The External Heat Recovery System
➤ Have stubborn clogging removed by an authorized KAESER SERVICE technician. Checking the cooler for leaks ➤ Carry out visual inspection: Did cooling oil escape? Is a cooler leaking? ➤ Have the defective cooler repaired immediately by a KAESER SERVICE technician. 10.6 Option W1 Maintaining the external heat recovery system Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.
Page 72: Air Filter Maintenance
Compressor motor maintenance The anti-friction bearings of the compressor motor are permanently greased. Re-greasing is not necessary. ➤ Have the anti-friction bearings checked by an authorised KAESER SERVICE technician in the course of a maintenance visit. Operating Manual Rotary screw compressor...
Page 73: Drive Belt Maintenance
Maintenance 10.9 Drive belt maintenance 10.9 Drive belt maintenance Material Spare parts (if required) Precondition The power supply isolating device is switched off, the device is locked off, the absence of any voltage has been verified. The machine has cooled down. WARNING Touching the moving drive belt may result in severe bruising or even loss of limb or extremi‐...
Page 74: Testing The Pressure Relief Valve
Maintenance 10.10 Testing the pressure relief valve Changing the belt 1. Loosen the locking nut 2. Turn adjusting nut to loosen the tension on the belt until it can be removed from the pulley. 3. Install the new belt and use the adjusting nut to adjust tension until the marker pin reaches the lower end of the elongated hole.
Page 75: Check The Safety Shut-Down Due To Excessive Airend Discharge Temperature
➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐ ual. The machine does not shut down? ➤ Have the safety shut-down function checked by an authorised KAESER SERVICE tech‐ nician. 10.12 Check the EMERGENCY STOP control device Fig.
Page 76: Venting The Machine (De-Pressurising)
Maintenance 10.14 Venting the machine (de-pressurising) In frequency-controlled compressors (SFC) the oil level indicator sis only accurate when the machine is running at or near maximum speed. The lower the pressure at the compressed air outlet, the higher the speed. Precondition The machine has been running at least 5 minutes under LOAD.
Page 77: Fig. 26 Venting The Machine
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact the authorised KAESER SERVICE. Manually venting the air cooler After shutting down the compressor and venting the oil separator tank, the machine is still un‐...
Page 78: Replenish Cooling Oil
Maintenance 10.15 Replenish cooling oil 2. Slowly open the shut-off valve to release pressure. 3. Disconnect the male hose fitting and close the shut-off valve 10.15 Replenish cooling oil The machine must be isolated from the compressed air network and completely vented be‐ fore undertaking any work on the pressure system.
Page 79: Topping Up With Cooling Oil And Trial Run
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact the authorised KAESER SERVICE. Manually venting the air cooler After shutting down the compressor and venting the oil separator tank, the machine is still un‐...
Page 80: Changing The Cooling Oil
Maintenance 10.16 Changing the cooling oil 4. Top up to bring the oil to the correct level. 5. Renew the filler plug's gasket if necessary and screw the plug into the filler port. Starting the machine and performing a trial run 1.
Page 81: Fig. 28 Changing The Cooling Oil, Oil Separator Tank
Maintenance 10.16 Changing the cooling oil Fig. 28 Changing the cooling oil, oil separator tank Hose coupling (air cooler venting) Shut-off valve open Pressure gauge Shut-off valve closed Hose coupling (oil separator tank venting) Maintenance hose Oil filler port with plug Hose coupling (oil drainage) Cooling oil level indicator.
Page 82: Fig. 29 Changing The Cooling Oil Oil Cooler
Maintenance 10.16 Changing the cooling oil Draining the oil from the separator tank Contact KAESER SERVICE if condensate is detected in the cooling oil. It is necessary to adapt the airend discharge temperature to individual ambient conditions. Precondition Cut-off the electrical power supply via the power supply isolating device, ensure that the device is locked off, verify the absence of any voltage.
Page 83: Fig. 30 Changing The Cooling Oil, Heat Recovery System
Maintenance 10.16 Changing the cooling oil Option W1 Draining the oil from the thermostatic valve A drain plug is provided to drain oil from the thermostatic valve. If the machine is connected to an external heat recovery system, oil should also be drained from the heat exchanger at a suitable point.
Page 84: Changing The Oil Filter
Maintenance 10.17 Changing the oil filter 10.17 Changing the oil filter The machine must be isolated from the compressed air network and completely vented be‐ fore undertaking any work on the pressure system. Material Spares Cooling oil receptacle Precondition The power supply isolating device is switched off, the device is locked off, the absence of any voltage has been verified.
Page 85: Changing The Oil Separator Cartridge
Maintenance 10.18 Changing the oil separator cartridge Starting the machine and carrying out a trial run 1. Close all access doors, replace and secure all removable panels. 2. Open the user's shut-off valve between the machine and the air distribution network. 3.
Page 86: Fig. 32 Changing The Oil Separator Cartridge
Maintenance 10.18 Changing the oil separator cartridge Fig. 32 Changing the oil separator cartridge Cover Screw connection Dirt trap seal Air pipe Oil separator cartridge Retaining screw Ball (functioning as a check valve) Self-locking nut Strainer Changing the oil separator cartridge 1.
Page 87 Maintenance 10.18 Changing the oil separator cartridge Start the machine and carry out a trial run 1. Close all access doors, replace and secure all removable panels. 2. Open the user's shut-off valve between the machine and the air distribution network. 3.
Page 88: Documenting Maintenance And Service Work
Maintenance 10.19 Documenting maintenance and service work 10.19 Documenting maintenance and service work Machine number: ➤ Enter maintenance and service work carried out in the list. Date Maintenance task carried out Operating hours Signature Tab. 53 Logged maintenance tasks Operating Manual Rotary screw compressor 901848 21 E...
Page 89: 11 Spares, Operating Materials, Service
➤ Please give the information from the nameplate with every enquiry and order for spares. 11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original components. They are specifically selected for use in KAESER machines. Unsuitable or poor quality consumable parts and operating fluids/materials may result in damage to the machine or impair its proper function.
Page 90: Replacement Parts For Service And Repair
Spares, Operating Materials, Service 11.4 Replacement parts for service and repair ➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement. Your advantage: lower costs and higher compressed air availability. 11.4 Replacement parts for service and repair Use this spare parts list to plan your material requirement according to operating conditions and to order the required spare parts.
Page 91 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operating Manual Rotary screw compressor 901848 21 E...
Page 92 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operating Manual Rotary screw compressor 901848 21 E...
Page 93 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operating Manual Rotary screw compressor 901848 21 E...
Page 94: 12.1 Decommissioning, Storage And Transport
Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning De-commissioning 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.
Page 95: Packing
Mass and centre of gravity determine the most suitable method of transportation. The centre of gravity is shown in the drawing in chapter 13.3. ➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐ tures.
Page 96: Transport With A Hoist
Attached components such as centrifugal separators, condensate drains or filters ■ Rain protection covers ➤ Consult KAESER if you require suitable load-carrying and attachment devices or have questions regarding the correct use. Precondition Load-carrying and attachment devices meet the local safety regulations.
Page 97: Fig. 34 Transporting With A Crane
Decommissioning, Storage and Transport 12.4 Transport Fig. 34 Transporting with a crane Load carrying devices Attachment resources Crossbeam 1. WARNING! Risk of accident caused by incorrect use of load-carrying and attachment devices! ➤ Comply with permissible load limits. ➤ Comply with specific safety information of used load-carrying and attachment devices. 2.
Page 98: Disposal
Decommissioning, Storage and Transport 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.
Page 99: 13 Annex
Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E...
Page 100 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E...
Page 101 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E...
Page 102 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E...
Page 103 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E...
Page 104 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Rotary screw compressor 901848 21 E...
Page 105: Pipeline And Instrument Flow Diagram (P&I Diagram) Modulating Control
Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control 13.2 Option C1 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E...
Page 106 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E...
Page 107 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E...
Page 108 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E...
Page 109 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E...
Page 110 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Rotary screw compressor 901848 21 E...
Page 111: Dimensional Drawing
Annex 13.3 Dimensional drawing 13.3 Dimensional drawing Operating Manual Rotary screw compressor 901848 21 E...
Page 112 Annex 13.3 Dimensional drawing Operating Manual Rotary screw compressor 901848 21 E...
Page 113 Annex 13.3 Dimensional drawing Operating Manual Rotary screw compressor 901848 21 E...
Page 114: Electrical Diagram
Annex 13.4 Electrical Diagram 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E...
Page 115 Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E...
Page 116 Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E...
Page 117 Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E...
Page 118 Annex 13.4 Electrical Diagram Operating Manual Rotary screw compressor 901848 21 E...
Page 119 7.3217.0 / QRUV 7.3217.0 / QRUV Switching element Schlegel Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO Control cabinet KAESER KAESER 7.7681.0 7.7681.0 7.7681.0 7.7681.0 7.7681.0 Mounting plate KAESER KAESER 212761.0 212761.0 212761.0...
Page 120 7.3217.0 / QRUV 7.3217.0 / QRUV Switching element Schlegel Schlegel 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO 7.3218.0 / MHTOO Control cabinet KAESER KAESER 7.7681.0 7.7681.0 7.7681.0 7.7681.0 7.7681.0 Mounting plate KAESER KAESER 212761.0 212761.0 212761.0...
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This manual is also suitable for:

Sk 22 Sk 25

KAESER SK Series Operating Manual

1 Regarding this Document Using this Document

2 Technical Specifications Nameplate

3 Safety and Responsibility Basic Instructions

4 Design and Function

5 Installation and Operating Conditions

6 Installation

7 Initial Start-Up Ensuring Safety

8 Operation

9 Fault Recognition and Rectification

10 1 Maintenance

11 Spares, Operating Materials, Service

12 1 Decommissioning, Storage and Transport

13 Annex

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