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Fig. 9 Compressed air connection

1

Axial compensator or hose

2

Shut-off valve

WARNING

Serious injury or death can result from loosening or opening components under pressure.
➤ Vent all pressurized components and chambers completely.

1. A shut off valve must be installed by the user in the connection line.
2. Make the compressed air connection with an axial compensator or hose.

6.4  Making the Power Supply Connection

Precondition All three phases of the power supply are isolated,

the disconnect device is locked in the off position,

a check has been made that no voltage is present.

1. Have the power supply connected by authorized installation personnel or an authorized electri‐

cian only.

2. Carry out safety measures as stipulated in relevant regulations (IEC 364, for example) and in

national accident prevention regulations (BGV A3 in Germany). In addition, observe the regula‐

tions of the local electricity supplier.

3. Test the overload protection cut-out to ensure that the time it takes to disconnect in response to

a fault is within the permitted limit.

4. Select supply cable conductor cross-sections and fusing in accordance with local regulations.
5. The user must provide the machine with a lockable power supply disconnecting device.

This could be, for example, a load disconnect switch with fused input. If a circuit breaker is used

it must be suitable for the motor starting characteristics.

6. Check that the tappings on the control voltage transformer are connected according to the supply

voltage.

If not, change the tappings to suit the power supply voltage.

DANGER

Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is

present.

7. Connect the machine to the power supply.

Further information The electrical diagram 13.4 contains further details of the power supply connection.

6

Installation

6.4

Making the Power Supply Connection

34

Service Manual    Screw Compressor  
SX SIGMA CONTROL BASIC

9_6919 04 E

Содержание SX

Страница 1: ...Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E Manufacturer KAESER KOMPRESSOREN GmbH 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com...

Страница 2: ...Original instructions KKW SSX 1 04 en SBA SCHRAUBEN SCB...

Страница 3: ...pecified Use 12 3 3 Improper Use 12 3 4 User s Responsibilities 12 3 4 1 Observe statutory and universally accepted regulations 12 3 4 2 Qualified personnel 13 3 4 3 Adherence to inspection schedules...

Страница 4: ...erved before before Every Start Up 36 7 3 Checking installation and operating conditions 37 7 4 Setting the overload protection cut out 38 7 5 Filling cooling oil into the airend 38 7 6 Checking direc...

Страница 5: ...4 10 15 Changing the oil filter 66 10 16 Changing the oil separator cartridge 67 10 17 Document maintenance and service work 69 11 Spares Operating Materials Service 11 1 Note the Nameplate 70 11 2 Or...

Страница 6: ...Contents iv Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 7: ...edging messages 44 Fig 16 Filter mat for the air and oil cooler 53 Fig 17 Control cabinet ventilation grill 54 Fig 18 Filter mat for the air and oil cooler 55 Fig 19 Air filter maintenance 56 Fig 20 C...

Страница 8: ...List of Illustrations vi Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 9: ...4 Mains supply 380V 3 60Hz 11 Tab 25 Mains supply 440V 3 60Hz 11 Tab 26 Mains supply 460V 3 60Hz 11 Tab 27 Inspection intervals according to Ordinance on Industrial Safety and Health 14 Tab 28 Danger...

Страница 10: ...List of Tables viii Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 11: ...tallation declaration Missing documents can be requested from KAESER Make sure all documents are complete and observe the instructions contained in them Make sure you provide the data from the namepla...

Страница 12: ...to safety are named that will help you to avoid dangerous situations This bullet is is placed by lists of actions comprising one stage of a task In lists of actions with several stages the sequence o...

Страница 13: ...aximum working pressure Ambient temperature Tab 2 Nameplate 2 2 Options The table contains a list of possible options Enter options here as a reference Option Option code Exists Modulating control C1...

Страница 14: ...mbient conditions SX 3 SX 4 SX 6 SX 8 Maximum altitude AMSL m 1000 1000 1000 1000 Permissible ambient tem perature C 3 45 3 45 3 45 3 45 Cooling air temperature C 3 45 3 45 3 45 3 45 Inlet air tempera...

Страница 15: ...st fan for forced ventilation Flow rate m3 h at 100 Pa 1000 1200 1500 2000 Tab 7 Ventilation 50Hz Mains frequency 60 Hz SX 3 SX 4 SX 6 SX 8 Inlet aperture Z see fig ure 8 m2 0 2 0 2 0 2 0 2 Extractor...

Страница 16: ...e air delivery FAD m3 min at 50 Hz Maximum working pres sure bar SX 3 SX 4 SX 6 SX 8 8 0 34 0 45 0 60 0 80 11 0 26 0 36 0 48 0 67 15 0 25 0 36 0 53 Tab 11 FAD 50 Hz FAD m3 min at 60 Hz Maximum working...

Страница 17: ...cosity at 40 C 45 mm2 s D 445 ASTM Test 44 mm2 s DIN 51562 1 50 7 70 0 mm2 s D 445 ASTM Test Viscosity at 100 C 7 2 mm2 s D 445 ASTM Test 6 8 mm2 s DIN 51562 1 8 2 710 4 mm2 s D 445 ASTM Test Flash po...

Страница 18: ...6 SX 8 8 5 3490 3520 3520 3540 11 3490 3520 3520 3540 15 3520 3520 3540 Tab 17 Drive motor rated speed 60Hz 2 12 Sound pressure level Operational state Nominal volume flow Nominal pressure Measuremen...

Страница 19: ...e machine may not be connected to a three phase supply in which one of the phases is earthed as this can lead to dangerous voltage surges Connection to an IT supply is not permitted without further me...

Страница 20: ...y to private power supplies within industrial areas isolated from the public mains Machines with current consumption 16 A 75 A comply fully with IEC 61000 3 12 The machines listed in table are intende...

Страница 21: ...t drawn A 6 7 9 12 Tab 24 Mains supply 380V 3 60Hz Rated power supply 440V 10 3 60Hz SX 3 SX 4 SX 6 SX 8 Mains fusing A 10 10 16 16 Supply cable mm2 4x1 5 4x1 5 4x2 5 4x2 5 Current drawn A 5 6 8 10 Ta...

Страница 22: ...e manual Operate the machine only within its performance limits and under the permitted ambient condi tions Do not use compressed air for breathing purposes unless it is specifically treated for such...

Страница 23: ...ppropriate measures to safeguard persons and property have received adequate training and authorisation for the safe installation and maintenance on this equipment Additional qualifications for compre...

Страница 24: ...e found here Electricity Allow only qualified and authorised electricians or trained personnel under the supervision of a qualified and authorised electrician to carry out work on electrical equipment...

Страница 25: ...enclosure while the machine is switched on Switch off and lock out the power supply disconnecting device and check that no voltage is present Wear close fitting clothes and a hair net if necessary Mak...

Страница 26: ...rms to local safety regulations Allow transport only by personnel trained in the safe movement of goods Attach lifting gear only to suitable lifting points Be aware of the centre of gravity to avoid t...

Страница 27: ...er these areas 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...

Страница 28: ...ne only with closed safety guards access doors and panels Switch off and lock out the power supply disconnecting device and check that no voltage is present before opening any machine enclosure or gua...

Страница 29: ...tment Our general terms and condi tions 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 under the conditions...

Страница 30: ...otection regulations Observe relevant national regulations This applies particularly to parts contaminated with cooling oil Do not allow cooling oil to escape to the environment or into the sewage sys...

Страница 31: ...ooling air flow The enclosure is not suitable for the following uses Walking on standing or sitting on As resting place or storage of any kind of load Safe and reliable operation is only assured with...

Страница 32: ...e oil then flows through the oil filter 4 and back to the point of injection Pressure within the machine keeps the oil circulating A separate pump is not necessary A thermostatic valve maintains optim...

Страница 33: ...d LOAD Contact open IDLE When the contact closes the machine switches to LOAD When the contact opens the machine switches to IDLE At the end of the idling period the machine switches to STANDSTILL and...

Страница 34: ...falls with the air demand The regulating valve is factory set The setting should not be changed without consultation with KAESER Service 4 6 2 Control modes Using the selected control mode the contro...

Страница 35: ...air delivery is continuously varied within the control range of the machine This control mode is not available on variable speed machines with a frequency controlled drive SFC Compressed Air Demand Op...

Страница 36: ...rameter list Reduces a parameter value 7 UP Scrolls up the parameter list Increases a parameter value 8 escape Exits the edit mode without saving 9 enter Enters edit mode Exits the edit mode and saves...

Страница 37: ...ning 1 xx x Current system pressure in bar psi or MPa 2 yy Current airend discharge temperature ADT in C or F 3 z Display of parameters and their settings see table 35 4 1 2 Error code for alarm and w...

Страница 38: ...displayed in either C or F 5 Units used for display of pressure The current working pressure can be displayed in bar psi or MPa 6 Control modes Factory setting OFF This parameter changes the control...

Страница 39: ...rs F Options The displayed value informs KAESER Service concerning the controller s internal ma chine configuration Tab 35 Parameter Further information Means of changing or adjusting parameters are g...

Страница 40: ...ts explosive or chemically unstable gases or vapours acid alkaline forming substances particularly ammonia chlorine or hydrogen sulphide Ensure sufficient and suitable lighting such that the display c...

Страница 41: ...ilation is insufficient a partial vacuum can be created in the room 1 Ensure that the volume of air flowing into the machine room is at least equivalent to that being removed from it by the machine an...

Страница 42: ...Further information on installation of exhaust air ducts can be found in chapter 13 3 5 3 Operating the Machine in an Air System If the machine is supplying an air system the system operating pressur...

Страница 43: ...ressed air system to ensure that no compressed air can flow back into the machine 2 Vent all pressurized components and chambers completely 3 Check all hose couplings in the compressed air system with...

Страница 44: ...electricity supplier 3 Test the overload protection cut out to ensure that the time it takes to disconnect in response to a fault is within the permitted limit 4 Select supply cable conductor cross se...

Страница 45: ...s 3 Use a screwdriver to open the spring loaded terminals and insert the ends of the conductors in the square openings above the corresponding terminals 4 Secure the cable so there is no tension on th...

Страница 46: ...Close shut off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow back into the machine 2 Vent all pressurized components and chambers co...

Страница 47: ...supply disconnecting device installed 6 4 Does the power supply conform to the specifications on the name plate 2 1 Are the power supply cable conductor cross sections and fuse ratings adequate 2 14 D...

Страница 48: ...e fluctuations temperature influences or component tolerances the setting can be higher than the arithmetical phase current Check the overload protection cut out setting The overload protection cut ou...

Страница 49: ...se sequence meter Switch the machine on and off again the moment the drive motor begins to turn Compare the direction of rotation of the motor with the arrows on the motor and the airend casing If the...

Страница 50: ...e at least once a week during the first 4 weeks of operation Condensate in the cooling oil Contact KAESER Service Further information Information on draining off cooling oil is given in chapter 10 14...

Страница 51: ...rease buffer capacity Setpoint pressure switching point 1 Scroll with the arrow keys until the parameter D setpoint pressure switch point is displayed in line 3 2 Press and hold enter for at least 3 s...

Страница 52: ...ntroller has carried out a self test the green controller ON LED lights continuously 2 Press the ON key The green Machine ON LED lights continuously If a power failure occurs the machine is not preven...

Страница 53: ...extinguishes 8 2 Switching Off in an Emergency and Switching On again The EMERGENCY STOP pushbutton is located below the control panel Fig 14 Switching off in an emergency 9 EMERGENCY STOP pushbutton...

Страница 54: ...ectify the fault and acknowledge the message with the acknowledge key alarm LED extinguishes The machine is now ready to start again Warning message Message coming LED flashes Message gone LED extingu...

Страница 55: ...not password protected Precondition The current parameter setting flashes Use the UP DOWN keys to change the value of the parameter and confirm with enter Changing a password protected parameter Some...

Страница 56: ...nterlocked access door open or panel removed Unlatch the EMERGENCY STOP pushbutton Close the access door or fit the panel 2 Motor alarm Overload protection of drive or fan mo tor if fitted Frequency c...

Страница 57: ...r housing exceeded Ensure adequate ventilation Ensure that the permissible room temperature is not exceeded 8 Spare Tab 39 Alarm indications 9 3 Warning messages he error code appears in the 4th line...

Страница 58: ...IDLE more than twice per minute Air receiver too small Increase size of air receiver Airflow into the compressed air network restricted Increase air pipe diameters Check filter elements The different...

Страница 59: ...is no voltage on floating relay contacts Working on pressure systems 1 Close shut off valves or otherwise isolate the machine from the compressed air system to ensure that no compressed air can flow...

Страница 60: ...counter counts down the operating hours to the next maintenance task The counter reading shows the number of operating hours to the next periodic machine maintenance Reset the counter to the original...

Страница 61: ...2 4 Cooling Oil Change Interval Duty cycles and ambient conditions are important criteria for the number and length of the change intervals KAESER Service will support you in determining suitable inte...

Страница 62: ...sks carried out punctually taking ambient and operating conditions into account Interval Service task Up to 12 000 h Have the valves checked Up to 12 000 h at the lat est every 3 years Check the drive...

Страница 63: ...acing the Control Cabinet Filter Mats Filter mats protect the control cabinet from ingress of dirt If the filter mats are clogged adequate cooling of the components is no longer ensured In such a case...

Страница 64: ...l 10 5 Cooler Maintenance Regular cleaning of the cooler ensures reliable cooling of the machine and the compressed air The frequency is mainly dependent on local operating conditions A leaking cooler...

Страница 65: ...ER service representa tive Checking the cooler for leaks Visual check Is cooling oil evident Is a cooler leaking Have the defective cooler repaired immediately by an authorized KAESER service repre se...

Страница 66: ...ive belts Material Spare parts if required Precondition The supply disconnecting device is switched off the device is locked off a check has been made that no voltage is present The machine has cooled...

Страница 67: ...ioning nut 3 until the markings 4 coincide 8 Tighten one fixing screw 1 to hold the motor in place then tighten the rest 1 and 2 Result The drive belts are sufficiently tensioned It is not necessary t...

Страница 68: ...15 bar should be tested only by KAESER Service Blow off protection and air system pressure monitoring are switched off during the test The machine must be isolated from the compressed air network and...

Страница 69: ...off or working pressure rises to 10 above the activating pressure of the pressure relief valve 4 If necessary vent the machine and replace the defective pressure relief valve Returning the machine to...

Страница 70: ...ine 1 Hose coupling air cooler venting 2 Pressure gauge 3 Hose coupling oil separator tank venting 6 Male hose coupling 7 Shut off valve A Shut off valve open B Shut off valve closed 8 Maintenance hos...

Страница 71: ...on from the shut off valve to the minimum pressure check valve 1 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 1 2 Slowly open the shut off valve 7 to release pr...

Страница 72: ...ally as soon as the machine is stopped Venting takes place in three stages Isolate the compressor from the air system Vent the oil separator tank Manually vent the air cooler WARNING Compressed air Co...

Страница 73: ...valve 1 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 1 2 Slowly open the shut off valve 7 to release pressure 3 Disconnect the male hose fitting 6 and close the...

Страница 74: ...fter a long period of standstill Material Cooling oil Cooling oil receptacle The maintenance hose with hose coupling and shut off valve is stowed beneath the oil separator tank WARNING There is risk o...

Страница 75: ...nance hose to the exter nal air supply 4 Open the shut off valve 7 until the pressure gauge on the oil separator tank reads 3 5 bar 5 Close the shut off valve 7 and remove the male hose fitting from t...

Страница 76: ...tween the machine and the compressed air network 3 Switch on the power supply and reset the maintenance interval counter 4 Start the machine and check the oil level again after about 10 minutes toppin...

Страница 77: ...r supply and reset the maintenance interval counter 4 After about 10 minutes check the oil level again and top up if necessary 5 Switch off the machine and check visually for leaks 10 16 Changing the...

Страница 78: ...ator cartridge anticlockwise and wipe off any drops of oil 2 Lightly oil the new filter s gasket 3 Turn the oil filter clockwise by hand to tighten Dispose of parts and materials contaminated with oil...

Страница 79: ...tenance and service work carried out in the list Date Maintenance task carried out Operating hours Signature Tab 46 Logged maintenance tasks 10 Maintenance 10 17 Document maintenance and service work...

Страница 80: ...al injury may result Use only genuine KAESER spares and operating materials Have an authorized KAESER Service Technician carry out regular maintenance Machine Name Quantity Number Air filter element 1...

Страница 81: ...the help of this parts list you can plan your material requirement according to operating conditions and order the spare parts you need Make sure that any service or repair tasks not described in thi...

Страница 82: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 72 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 83: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 73...

Страница 84: ...ed no pressure 1 Allow the machine to cool down completely 2 Disconnect all air and electrical connections 12 2 Packing A wooden crate is required for overland transport to protect the machine from me...

Страница 85: ...he forks are fully under the machine Fig 28 Transporting with a forklift truck Drive the forks completely under the machine or palette and lift carefully 12 4 3 Transporting with a crane Suitable lift...

Страница 86: ...tion 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 Co...

Страница 87: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 77...

Страница 88: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 78 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 89: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 79...

Страница 90: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 80 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 91: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 81...

Страница 92: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 82 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 93: ...e and Instrument Flow Diagram P I diagram MODULATING control mode 13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_6919 04 E Service Manual Screw Compressor SX SIGM...

Страница 94: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 84 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 95: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 85...

Страница 96: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 86 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 97: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 87...

Страница 98: ...13 Annex 13 2 Pipe and Instrument Flow Diagram P I diagram MODULATING control mode 88 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 99: ...13 3 Dimensional Drawing 13 Annex 13 3 Dimensional Drawing 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 89...

Страница 100: ...13 Annex 13 3 Dimensional Drawing 90 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 101: ...13 Annex 13 3 Dimensional Drawing 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 91...

Страница 102: ...13 4 Electrical Diagram 13 Annex 13 4 Electrical Diagram 92 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 103: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 93...

Страница 104: ...13 Annex 13 4 Electrical Diagram 94 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 105: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 95...

Страница 106: ...13 Annex 13 4 Electrical Diagram 96 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 107: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 97...

Страница 108: ...13 Annex 13 4 Electrical Diagram 98 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 109: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 99...

Страница 110: ...13 Annex 13 4 Electrical Diagram 100 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 111: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 101...

Страница 112: ...13 Annex 13 4 Electrical Diagram 102 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 113: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 103...

Страница 114: ...13 Annex 13 4 Electrical Diagram 104 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 115: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 105...

Страница 116: ...13 Annex 13 4 Electrical Diagram 106 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 117: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 107...

Страница 118: ...13 Annex 13 4 Electrical Diagram 108 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

Страница 119: ...13 Annex 13 4 Electrical Diagram 9_6919 04 E Service Manual Screw Compressor SX SIGMA CONTROL BASIC 109...

Страница 120: ...13 Annex 13 4 Electrical Diagram 110 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

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Страница 122: ...13 Annex 13 4 Electrical Diagram 112 Service Manual Screw Compressor SX SIGMA CONTROL BASIC 9_6919 04 E...

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