Service Manual Kaeser SK 19

SERVICE MANUAL USE
Screw Compressor
Model: SK 19
GL---Nr.: BA---SK19.L---1.9760.50011---00
Index: 001101
L . . . . . . . . . . . . . . . . . . . . . . . . . . Volt L Cabinet heaters

L Wye---Delta Start L 115 V receptacle
L D.O.L. Start L Outdoor modification
L . . . . . . . . . . . . . . . . . . . . . . . . . . psig L Rainhoods
L ............................. L Switchable Modulation
L ............................. L Synthetic lubricant . . . . . . . . . . . . . . . . . . .
L Wiring Diagram: L Food Grade lubricant . . . . . . . . . . . . . . . . .
..............................
Serial No.: ...............................................

Table of Contents
Chapter --- Page
1 Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1

1.1 Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.2 Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.3 Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.4 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1
1.5 Set Point of the Safety Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.6 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.7 Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 2
1.8 Oil recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 3
1.9 Maintenance for the Electrical Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 5
1.10 Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 5
2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

2.1 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.2 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7
2.3 Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.4 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.5 Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 8
2.6 Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 9
3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.1 Proper use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.2 Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.3 Compressed Air Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
3.4 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 10
4 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.1 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
4.2 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 11
5 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 12

5.1 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 12
5.2 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 12
5.3 Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . 5 --- 12
5.4 DUAL Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 15
5.5 QUADRO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 16
5.6 VARIO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 17
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.1 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 18
6.2 Connection of the Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
6.3 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 19
i
Table of Contents
Chapter --- Page
7 Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 20

7.1 Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . 7 --- 20
7.2 Points to be Observed before Starting the Compressor Unit . . . . . . . . . . . . . . . 7 --- 20
7.3 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 22
7.4 Measures to be taken before Initial Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.4.1 Pour a small quantity of oil into the air inlet port . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.4.2 Running the compressor in idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 23
7.5 Functional Check of the Door Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 24
7.6 Motor Overload Relay Adjustment and Changing . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 25
7.7 Setting the Air System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 27
8 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.1 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.2 SIGMA controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.3 Emergency Stop Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 28
8.3.1 Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 29
8.3.2 Light emitting diodes and plain text display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 29
8.4 Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 30
8.5 Acknowledgement of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 30
8.6 Acknowledgement of Service Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 31
9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 32
9.1 Observe the following rules during all maintenance and servicing work: . . . . . 9 --- 32
9.2 Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 33
9.3 Opening and Closing the Compressor Package . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 34
9.4 Checking the Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 35
9.5 Drive Belt Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 35
9.6 Cleaning or Replacing the Filter Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 36
9.7 Cleaning or Replacing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 37
9.8 Servicing the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 38
9.9 Testing the Safety Relief Valve on the Oil Separator Tank . . . . . . . . . . . . . . . . . . 9 --- 39
9.10 Venting the compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 39
9.11 Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 40
9.11.1 Removal and replacement of the oil filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 40
9.12 Oil Top ---Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 41
9.13 Cleaning the Oil Cooler and Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 43
9.13.1 Removing and cleaning the oil cooler/air aftercooler . . . . . . . . . . . . . . . . . . . . . . 9 --- 43
9.14 Oil Change (Oil Separator Tank and Oil Cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 45
9.14.1 Oil change using external pressure source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 46
9.14.2 Oil top ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 47
9.14.3 Draining the oil using own compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 48
9.14.4 Procedure for putting back into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 48
9.15 Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 49
9.16 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 51
10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52

10.1 Service parts and maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
10.2 Service and Maintenance Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52
ii
Table of Contents
Chapter --- Page
11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 53
11.1 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 53
11.2 Trouble shooting: Possible cause---Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 70
11.2.1 Airend temperature is too high (greater than 167F---200F) . . . . . . . . . . . . . . . 11 --- 70
11.2.2 Motor overload relay switches the unit off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 70
11.2.3 Compressor is running but produces no pressure . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 71
11.2.4 Oil leaks out of air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 72
11.2.5 Full---load/Idle sequence occurs too frequently (short cycles) . . . . . . . . . . . . . . 11 --- 72
11.2.6 Safety relief valve blows off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 72
11.2.7 Oil inside the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 72
11.2.8 Excessive oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 73
iii
Technical Specification
1 Technical Specification
1.1 Compressor Unit

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SK 19
Maximum gauge working pressure . . . . . . . . 110/125/145/190 psig
Minimum gauge working pressure . . . . . . . . . . . . . . . . . . . . . . 80 psig
Free air delivery at max. gauge . . . . . . . . . . . . . . 68/ 64/ 58/ 45 cfm
working pressure
Operating temperature approx. . . . . . . . . . . . . . . . . . . . 167---200 EF
(Varies with ambient temperature and operating conditions)
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 595 lbs
Drawings:
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 7471.5
P & I flow chart . . . . . . . . . . . . . . . . . . . . . . FSK19STL---00022.00
(Pipework and instrument flow chart)
Electrical diagram . . . . . . . . . . . . . . . . . . . . . SSK19.Y---U1013.00
1.2 Noise Level

Noise level to CAGI---Pneurop . . . . . . . . . . . . . . . . . . . . . . . . . . 67 dB(A)
at 1 m distance (free sound field measurement)
1.3 Motor
Compressor motor:
Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 hp
Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 rpm
Specification class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEFC
V-- belt set for:
110 psig Compressor unit --- Part number . . . . . . . . . . 6.2502.0
1.4 Electrical Connection

Main voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230 V 3---phase
Full load current FLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.2 A
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Recommended main disconnect fuses
(Dual element or time---delay) . . . . . . . . . . . . . . . . . . . . . . . . . . 60 A
Recommended power supply cable (CU multi---stranded)
cross---section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 AWG
1 --- 1
Mains voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 V 3---phase

Full load current FLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.6 A
Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz
Recommended main disconnect fuses
(Dual element or time---delay) . . . . . . . . . . . . . . . . . . . . . . . . . . 30 A
Recommended power supply cable (CU multi---stranded)
cross---section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 AWG
Attention! Maximum dual element time -- delay fuses are selected according to
1996 N.E.C. Article 240 -- 6, 430 -- 52 and Tables 430 -- 148 & 150.
Select multi-- strand copper core wire at 40C ambient temperature

according to 1996 N.E.C. 110 -- 14(c), 220 -- 3, 310 -- 15, Table 310 -- 16,
430 -- 6, 430 -- 22 and Tables 430 -- 148 & 150.
For electrical power supply please refer to chapter 2.3 and 6.3
1.5 Set Point of the Safety Relief Valve

110 psig Compressor Unit --- Activating pressure . . . . . . . . 140 psig
1.6 Installation Requirements

Max. height above sea level of the place of installation . . 3000 ft.
(for all heights above please contact authorized KAESER distributor)
Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 EF
Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 EF
Min. cooling air/inlet air temperature . . . . . . . . . . . . . . . . . . . . 40 EF
Max. cooling air/inlet air temperature . . . . . . . . . . . . . . . . . . . 105 EF
Air inlet opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 sq.ft.
Exhaust air for solution A (see chapter 6.1):
Forced ventilation with exhaust ventilator . . . . . . . . . . . . . . 2350 cfm at static pressure of
0.4 inches water column
Exhaust air for solution B (see chapter 6.1):
Exhaust air used for space heating:
Heating duct w x h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14” x 20”
1.7 Oil Capacities

Total oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17 gal
After oil change or after long period of storage

Quantity required for prelubrication of the airend . . . . . . . . . 0.5 quart
(Refer to chapter 7.4.1)
1 --- 2
1.8 Oil recommendations

Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can
form in compressor oils. These deposits block the flow of lubricant and cause excessive
wear and failure of moving parts. Contamination of the oil can allow the formation of acids,
causing extensive internal corrosion. Water may be condensed decreasing the oil’s lubric-
ity.
Oil in rotary compressors does much more than lubricate. During the compression pro-
cess, it acts as a sealant in the airend which is important for maximum efficiency. The lu-
bricant also absorbs much of the heat of compression to cool the airend and reduce the
temperature of the compressed air. It’s not enough that a compressor fluid lubricates well,
it must stand up to the heat, pressure and contaminants that are present in every air com-
pressor.
KAESER COMPRESSORS has several lubricants available that are specially formulated to
match these demands. They feature excellent lubricity, outstanding demulsibility (ability to
separate from water), and long life.
RECOMMENDED KAESER LUBRICANTS
SIGMA DESCRIPTION MAXIMUM RECOMMENDED

LUBRICANT CHANGE INTERVAL*
First Oil Change Subsequent Oil

Change
M---460 ISO 46 Semi---Synthetic Lubricant 2,000 Hours 4,000 Hours

S---460 ISO 46 Synthetic Lubricant 6,000 Hours 8,000 Hours
* Oil changes may need to be more frequent depending on ambient conditions.

When high ambient temperatures or dirty conditions are present, oil changes may be
necessary every 1,000 hours (4,000 hours for synthetic) or even shorter intervals. Oil
change intervals required should be determined through periodic oil analysis.
M -- SERIES SEMI -- SYNTHETIC LUBRICANTS
- M---Series SIGMA compressor fluids are the highest quality petroleum lubricants.
M---460 is specially blended to provide reliable performance in KAESER screw com-
pressors.
S-- SERIES SYNTHETIC LUBRICANTS
- S---Series SIGMA compressor oils are formulated from the most advanced synthetic
lubricants. 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 consistant 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 40F and 105F.
Specialty KAESER LUBRICANTS
- S---680 lubricant may be used when ambient temperatures are always between 70F
and 105F.
- 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
1 --- 3
21 CFR §178.3570 and is USDA H---1 approved. FG---460 is approved for canning,
food packing, meat and poultry processing and other applications where incidental
food contact may occur.
SPECIALTY KAESER LUBRICANTS

(Refer to product information to determine suitability.)
SIGMA DESCRIPTION MAXIMUM RECOMMENDED

LUBRICANT CHANGE INTERVAL*
First Oil Change Subsequent Oil

Change
S---680 ISO 68 Synthetic Lubricant 6,000 Hours 8,000 Hours

FG---460 ISO 46 Food Grade Synthetic
Lubricant 3,000 Hours 4,000 Hours
* Oil changes may need to be more frequent depending on ambient conditions.

When high ambient temperatures or dirty conditions are present, oil changes may be
necessary every 1,000 hours (4,000 hours for synthetic) or even shorter intervals. Oil
change intervals required should be determined through periodic oil analysis.
General Information
KAESER synthetic lubricants should be stored in a protected location to prevent conta-
mination. Do not re---use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER syn-
thetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classi-
fied as a fire---resistant fluid. It has a flash point above 460F. Since the user has total con-
trol over the conditions of the compressor lubricant, he assumes total responsibility for its
safe usage.
Material Safety Data Sheets are available for each lubricant from your KAESER authorized
distributors.
Regardless of the lubricant selected, the KAESER Sigma lubricants will separate readily
from water. 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 9.14 proper draining procedure.
Compatibility of KAESER Sigma Lubricants
All the above listed KAESER Sigma lubricants are similar to mineral oil in their compatibility
with paints, seals, gaskets and hoses. The typical precautions are required when changing
over from mineral oil to KAESER synthetic hydrocarbon based lubricant.
Never mix lubricants of different types or brands.
When switching from mineral oil to a synthetic oil, the plant’s system materials must be
re---evaluated. Certain plastics are not compatible with synthetic oils. The following is a par-
tial list of acceptable and not recommended materials:
1 --- 4
ACCEPTABLE NOT RECOMMENDED
Viton Celcon PVC

High Nitrile Buna N Neoprene ABS
Teflon SBR Rubber
Epoxy Paint Low Nitrile Buna N
Oil Resistant Alkyd Acrylic Paint
Nylon Lacquer
Delrin Polystyrene
Attention! Polycarbonate bowls can be etched by any synthetic lubricant.

We recommend replacement with metal bowls, or the addition of metal
guards.
1.9 Maintenance for the Electrical Motor

Relubricate the compressor motor bearings:
Under normal operating conditions, after . . . . . . . . . . . . . 12000 h*
(ambient temperature up to 77EF)
Under unsuitable conditions, after . . . . . . . . . . . . . . . . . . . . 6000 h*
(ambient temperature up to 105EF)
but no later than . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Years
* operating hours
1.10 Dimensional Drawing

(see following page)
1 --- 5
1 --- 6
Safety
2 Safety Regulations
Read this service manual carefully and observe cautionary references before putting this
compressor package into operation and before carrying out any maintenance.
2.1 Explanation of Symbols and References

This symbol is placed before all references to safety where danger to
life and limb can occur during work. It is especially important that
these rules are observed and that extreme care is taken in these
cases. For their own protection, all other users must be informed of
these safety rules. Observe general safety and accident prevention
regulations as well as the safety rules laid down in this service man-
ual.
Attention! This symbol is placed by text where considerable attention must be

paid so that recommendations, regulations, references and correct se-
quence of work are adhered to and that damage and/or destruction of
the compressor unit and/or other equipment is prevented.
This symbol identifies environmental protection measures.
This symbol indicates operations to be carried out by the operator or

service technician.
- This bullet identifies listings.
Explanation of warning labels

Beware of hot surface. Do not touch surface; danger of burning.
Beware of life -- threatening electricity. Do not touch electrical compo-

nents; danger of electric shock.
Beware of rotating parts. Do not touch rotating parts as this can cause
pinching/injury.
2.2 General Safety Precautions

Work on power driven systems may only be carried out by trained or
specialized personnel.
Prior to working on electrical systems of the compressor always per-

form the following steps in the sequence shown.
1. Lock the main disconnect in the ”off” position in accordance with

applicable lock out/ tag out procedures (example: OSHA CFR 29
§ 1910.147) to ensure the compressor does not restart.
2. Ensure the package cannot be switched on again
3. Check that no voltage is present
4. Lock the isolation shut-- off valve in the ”closed” position and vent
all compressed air trapped between the compressor and the isolation
shut-- off valve in accordance with applicable lock out/ tag out pro-
cedures (example: OSHA CFR 29 § 1910.147).
2 --- 7
Safety
Attention! Any alterations or reconstruction carried out without the prior written
authorization of KAESER COMPRESSORS Inc. will invalidate the war-
ranty.
- Do not allow open flame and flying sparks at the installation site.
- Take necessary precaution when welding on or near the compressor package to en-
sure that sparks or high temperatures cannot cause fire or explosion.
- Ensure that the compressor package is supplied only with clean uncontaminated air.
- Do not allow the maximum ambient temperature to be exceeded (see chapter 1.6),
unless special measures have been agreed upon between the manufacturer and the
customer.
- Perform oil changes according to the service manual or at least once annually (see
chapter 9.12).
- Do not mix cooling oils of different types.
- Maintain and monitor the operating temperature according to the manufacturer’s
specifications to avoid build ---up of condensate or varnish in the oil circuit (see
chapter 1.1).
- Use only cooling oils recommended by the manufacturer (see chapter 1.8).
- If maintenance work is carried out on any part of the oil circulation system, top off the
oil in the oil separator tank to the maximum level, run the compressor and keep it
under constant observation for a short period. Check the oil level again and top off
with oil to replace the oil taken up by the piping and the cooling system.
- Operation of compressor package is not recommended if the differential pressure
across the separator cartridge is greater than 14.5 psi. Check periodically.
2.3 Electrical Power Supply
Attention! The main power supply and overcurrent protection must be installed
by a qualified electrician in accordance with NEC, OSHA and any appli-
cable local codes.
Compressor packages must be installed with a lockable main discon-

nect and fuses or other short-- circuit and ground fault protection de-
vice.
For fuse and wire recommendations, see chapter 1.4
Please note that the conductors, fuses and procedure are KAESER’s
recommendations. These recommendations do not supersede other
applicable codes.
2.4 Spare Parts

Safe and reliable operation of the compressor package is guaranteed only with KAESER
original spare parts and KAESER SIGMA cooling oil.
2.5 Compressed Air System

If a compressed air system is extended or changed, verify that the blowoff pressure and
capacities of the safety relief valves on the air receiver tanks and in the system match the
rating of all the compressor packages installed.
2 --- 8
Safety
2.6 Environmental Protection

Condensate drainage
The condensate accumulating during compression must be fed via a

suitable drainage system, collected in special canisters and disposed
of according to environmental regulations.
Maintenance materials/wear items/replacement parts
Ensure that all wear items, maintenance and replacement parts accu-
mulating during operation of the compressor package are disposed of
according to environmental regulations.
The following points must be observed:
Avoid contact with skin and eyes.

Do not inhale vapors and oil mist.
Do not eat or drink when handling such materials.
Fire, open flame and smoking are strictly forbidden.
2 --- 9
General
3 General
The service manual must always be available for use at the location of
the compressor package.
The right is reserved to make technical changes and improvements to equipment which
may then result in discrepencies in the details of that equipment contained in this manual.
3.1 Proper use of the Compressor

The compressor package is intended solely for the purpose of generating compressed air.
Any further use outside of this purpose is considered improper. The manufacturer cannot
accept liability for any damage caused by such improper use; the user alone is liable for
any risks incurred.
Proper use of the compressor also includes adherence to the installation, removal, applica-
tion, operational and maintenance instructions laid down by the manufacturer.
3.2 Improper use

Never direct compressed air toward persons. Compressed air is a con-
centrated form of energy and as such is dangerous to life.
3.3 Compressed Air Treatment

Never use compressed air from oil injected compressor packages for
breathing purposes and production methods where the air has direct
contact with food, without subjecting the compressed air to additional
treatment.
3.4 Copyright
KAESER COMPRESSORS, INC.
All rights reserved. No part of this manual may be reproduced in any form without per-
mission of KAESER COMPRESSORS, INC.
3 --- 10
Transport
4 Transport
4.1 Transport Instructions

We recommend a fork lift truck or lifting equipment for transporting the compressor pack-
age to avoid damage to the cabinet and framework.
min. 40”
Spreader bar
Attention :
Do not exert any side forces on the compressor
unit when transporting with lifting equipment!
4.2 Packaging
The packaging provided with this compressor as delivered is intended to safeguard the
package against normal road transport damage. Please dispose of in an environmentally
friendly way and arrange for it to be recycled if possible.
4 --- 11
Construction and Operation
5 Construction and Operation
5.1 Principle of Compression

The stationary compressor package is fitted with a single stage, oil---injected airend. The
two rotors, the driven male rotor and the female rotor, both mounted in antifriction bear-
ings, are fitted into the airend. As the rotors rotate, air is drawn into the upper side through
the inlet port and is compressed on the lower side. The oil that is injected into the lower
side absorbs heat generated by compression, prevents metal to metal contact between
the rotors, seals the rotors and the housing from each other and also lubricates the antifric-
tion bearings. The compressed air and oil mixture leaves the airend via the discharge port.
4 5 1 2 3
1 Drive shaft 4 Male rotor
2 Oil injection 5 Female rotor
3 Discharge port 6 Air inlet port
5.2 Brief Description

The compressor block is driven by an electric motor via V---belts.
An oil separator cartridge is fitted into the oil separator tank allowing practically oil free
compressed air supply.
The control system of the compressor package ensures that compressed air is generated
within the set pressure limits.
Safety devices protect the compressor package against failure of important systems
through automatic shut ---down.
The fan ensures ventilation of the compressor package and sufficient cooling air for the
air---cooled oil cooler and air aftercooler.
5.3 Pipe and Instrument Flow Diagram (P & I Diagram)

(see following pages)
5 --- 12
5 --- 13
5 --- 14
5.4 DUAL Control
p
max
Pressure
p
min
1 2 3 4 5
Full load t1 t2
Motor power
Idle
Standstill
Time
In DUAL Control (combined idle and start ---stop) the compressor normally runs at full --
load, idle or standstill.
The controller regulates the compressor package between full -- load and idle.
If the compressor package runs in idle for longer than the preset period (1) to (2), for
example t1 = 6 min, the drive motor is stopped completely (2). When the lower switching
point p min (3) is reached the compressor package is automatically started again. Pressure
rises to the upper switching point p max (4), and the compressor package switches to idle. If
the pressure falls again to, for example, p min (5) within a shorter period (4) to (5), then the
compressor is automatically switched from idle to full---load.
5 --- 15
5.5 QUADRO Control
p
max
Pressure
pmin
Full load
Motor power
Idle
Standstill
1 2 1 3 1 4 1 2 1 4 5 1
Time
tp rise
tp decay
Running period
Idle/
standstill period
Run ---on period
Stop point for the running period or idle / standstill period

pmax upper switching point
pmin lower switching point
tp rise pressure rise time (the time during which the air system pressure rises
from the lower to the upper switching point)
tp decay pressure decay time (the time during which the air system pressure decays
from the upper to the lower switching point)
Functional description
Two fixed periods --- the running period and idle/standstill period --- are taken as the crit-
erium for selection of the operating mode of the compressor package when the air mains
pressure reaches the upper switching point. These two periods are set according to the
maximum permissible cut ---in frequency of the compressor motor.
The running period starts every time the compressor package is switched on. It lasts as
long as the compressor motor runs and stops when the compressor package switches to
full stop.
The idle/standstill period starts every time the operating mode changes from full load to off
load running. It runs during idle and also when the compressor package is switched to
standstill after the idle period. It stops when the compressor package switches to full load.
Every switching off point is delayed by the run ---on period, during which time the com-
pressor package vents.
The following switching cycles are possible:
- If the air systems pressure decays to the lower switching point, the compressor pack-
age switches to full load (1) irrespective of its previous operating mode. If the com-
pressor motor was at a standstill the opening of the inlet valve is delayed to allow an
unloaded compressor package start.
5 --- 16
- If the air systems pressure rises to the upper switching point and the running period
has already expired, the compressor package is switched off after the run ---on period
has expired (2).
- If the air systems pressure rises to the upper switching point before the running period
has expired then the pressure decay time of the previous switching cycle is taken as
the criterium for the selection of the operating mode:
-- If the pressure decay time tp decay was longer than the period set for the idle/standstill
period, the compressor is switched to standstill after the run ---on period has ex-
pired (3).
-- If the pressure decay time tp decay was shorter than the period set for the idle / stand-
still period, the idle mode is selected (4), that is, the inlet valve closes and the com-
pressor is vented with running motor. When the running period expires the com-
pressor package switches to standstill only after the run ---on period has also
expired (5).
5.6 VARIO Control

Functional description:
The idle period is automatically lengthened or shortened by the variable idle control in rela-
tion to the number of motor starts. The number of motor starts during the preceding hour
are measured.
A high switching frequency leads to longer idle periods.
A low switching frequency leads to shorter idle periods.
5 --- 17
Installation
6 Installation
6.1 Installation Requirements

Attention! The compressor should be mounted on level surface.
For any special application please consult with the manufacturer.
Safe operation of the compressor package is only ensured if the ambient temperature re-
mains within the limits stated in chapter 1.6).
If the compressor is used in the open, take care that it is protected against the direct rays
of the sun and against the ingress of dust and rain.
Install the compressor according to the following diagram. Adhere to the minimum dis-
tances shown to allow free access to the compressor package.
Adequate ventilation of the compressor space is ensured only if the minimum values (see
chapter 1.6) are adhered to.
A 20
B
b
30
min. 90
min.
22
35
min. 90
Exhaust ventilator
Exhaust A
duct
min. 90
B
h Air inlet
40
opening
32 32
Measurements in inches
Solution A: Forced Ventilation

The ventilator intended for the compressor room must provide adequate ventilation in rela-
tion to the size of the compressor package (see chapter 1.6).
6 --- 18
Installation
Solution B: Exhaust Air used for Space Heating

The hot air is forced through a conduit (see chapter 1.6) into the room to be heated.
Attention! Consult the manufacturer with regard to length of conduit and for
maximum allowable pressure drop for this compressor package.
Safe operation of the compressor package is guaranteed only if the temperature limits (see
chapter 1.6) of the cooling air are adhered to.
6.2 Connection of the Compressed Air Supply

Attention! The unit is set up ready to operate. Connect the discharge outlet of the
compressor to the system pipework using a flexible hose line and
isolation shut-- off valve with drain.
Use the NPT adapter if necessary.
6.3 Electrical Connection

The main power supply and overcurrent protection must be installed
by a qualified electrician in accordance with NEC, OSHA and any appli-
cable local codes.
For fuse and wire recommendations, see chapter 1.4
The compressor is wired ready for connection to the main supplies. Feed the supply cable
with cores marked L1, L2, L3 and PE through the cable inlet in the base frame into the con-
trol box and connect to the terminals marked L1, L2, L3 and PE in this box.
Attention! Maximum dual element time -- delay fuses are selected according to
1996 N.E.C. Article 240 -- 6, 430 -- 52 and Tables 430 -- 148 & 150.
Select multi-- strand copper core wire at 40C ambient temperature

according to 1996 N.E.C. 110 -- 14(c), 220 -- 3, 310 -- 15, Table 310 -- 16,
430 -- 6, 430 -- 22 and Tables 430 -- 148 & 150.
Wire temperature rating:
1.25 x FLA wire correction factor

(see chapter 1.4) temperature rating for 40C
100A 60C 0.82
> 100A 75C 0.88
6 --- 19
Initial Start
7 Putting into Operation
7.1 Points to be Observed before Putting into Operation

Every compressor package is given a test run at the factory and carefully inspected before
shipment. The test run confirms that the package conforms to the specification data and
runs perfectly. However, the compressor package could be damaged during transport. For
this reason, we recommend that the package be examined for possible shipping damage.
It is recommended that an operator observe the compressor package carefully during the
first hours of operation for any possible malfunction.
Attention! Important functional components in the compressor package (such as

minimum pressure check valve, safety relief valve, inlet valve and com-
bination valve) are adjusted and fitted to factory standards and specifi-
cations. Alterations to these components are not allowed without prior
written authorization with the manufacturer.
Do not disassemble the minimum pressure check valve, safety relief

valve, inlet valve and v-- belt tensioning devices. They are heavily
spring loaded.
Disassembly by unqualifed personnel may result in personal injury or

equipment damage.
7.2 Points to be Observed before Starting the Compressor Unit

ANY NON -- OBSERVANCE OF THIS OR OTHER REFERENCES (WARN-
ING; ATTENTION; DANGER ) CAN LEAD TO ACCIDENTS CAUSING IN-
JURY TO PERSONS OR DAMAGE TO EQUIPMENT.
If a power failure occurs, the compressor package will start again

automatically (normal setting) when the power is restored provided the
system pressure is lower than the cut-- in pressure entered in the
SIGMA CONTROL.
Do not operate the compressor with open maintenance doors or with

cover panels removed as personnel could be injured by rotating parts
and electrical equipment.
Remove all packaging materials, tools and transport securing devices on and in the
compressor package.
- The operator is expected to practice safe working techniques and to follow all recom-
mended operating and safety regulations when operating this compressor package.
- The operator of this compressor package is responsible for its safe operating condi-
tion.
- Do not operate this compressor package in locations where high dust conditions, poi-
sonous, or flammable gases could exist.
- Do not connect the compressor package to a supply voltage other than that stated on
the nameplate.
- Do not install the compressor package in a location subject to freezing temperatures.
The air temperature requirements at the air intake must be complied with (see
chapter 1.6).
7 --- 20
Initial Start
- If exhaust air ducts are to be installed the duct cross section must be equal or larger
than the cooling air outlet of the compressor package and may not exceed the per-
mitted pressure loss prescribed by the compressor manufacturer.
- During installation of the compressor package, ensure that a distance of at least 40 ”
is kept between the air intake of the unit and any wall.
Check the oil level in the oil separator tank (see chapter 9.12).
- Check that the airend rotates in the correct direction (see chapter LEERER MERKER).
Check the tension of the drive belts (see chapter 9.4).
The ball valve (6.6, see chapter 5.3) must be closed.
The ball valve (20, see chapter 5.3) must be open.
Lock the main disconnect in the ”off” position in accordance with ap-
plicable lock out/tag out procedures (example: OSHA CFR 29
Check all screws on the electrical connections for tightness and

tighten if necessary (carry out this check again after 50 hours of oper-
ation).
- This compressor is fitted with a run ---in oil filter cartridge. Replace the filter cartridge
after the run ---in period of 200 hours (see chapter 9.11).
7 --- 21
Initial Start
7.3 Checklist
Is the floor at the place of installation solid and level?
yes no
Is the space large enough for the compressor package or its components?
yes no
Are inlet and exhaust air apertures available in sufficient size and number?
yes no
Are all components of the compressor package easily accessible?
yes no
Is the power supply cable of sufficient cross---section?
(have electrical connection carried out by qualified electrician or company familiar with
local conditions)
yes no
Is a shut off valve fitted by the user?
yes no
Is a flexible connecting hose or axial compensator fitted between the compressor
package and the compressed air system?
yes no
Have all screws, bolts and electrical connections been checked for tightness?
yes no
Has the oil level in the oil separator been checked?
yes no
Is a main disconnect switch fitted (suited to the motor starting characteristics)?
yes no
Has the setting of the drive motor overload current trip been checked?
yes no
Have you ensured that there are no other air components located in the exhaust air flow
of the compressor package?
yes no
Have service personnel been instructed on safety regulations?
yes no
7 --- 22
Initial Start
7.4 Measures to be taken before Initial Start

Follow the procedure detailed bellow before initial start, after an oil change or if the com-
pressor has not been operated for a period of three months or longer before starting the
compressor:
7.4.1 Pour a small quantity of oil into the air inlet port
Do not add oil unless the compressor package is completely vented.
See chapter 9.10 to vent the compressor.

To pour in the oil, unscrew the filler plug (1) on the inlet valve (2) and then pour the
prescribed quantity of oil (see chapter 1.7) into the airend.
Manually rotate the airend in a counter clockwise direction with the drive belts.
Screw the filler plug (1) back in.
Attention! This oil must be of the same type as the oil used to operate the com-
pressor (see label near the oil filler plug on the oil separator tank).
If no additional oil is available, remove required amount of oil from the

oil separator tank. See chapter 9.14 for this procedure.
If the compressor unit was at standstill for more than 12 months, addi-
tional precautionary steps have to be taken before putting the unit
back into operation. In this case consult the manufacturer.
Open the isolation shut ---off valve between the compressor and the compressed air
system.
1 Filler plug
2 Inlet valve
7.4.2 Running the compressor in idle

At initial start run the compressor package in idle for 20 seconds by pressing the load/idle
key (5, see chapter 8.3.1).
This measure ensures that the compressor package has sufficient time to flood the oil cir-
culation.
If a power failure occurs, the compressor package will start again
automatically (normal setting) when the power is restored provided the
system pressure is lower than the cut-- in pressure entered in the
SIGMA CONTROL.
7 --- 23
Initial Start
7.5 Functional Check of the Door Interlock Switch

Do not operate the compressor unit with a malfunctioning door inter-
lock switch.
Do not attempt to modify or by-- pass the door interlock switch.
1 Door interlock switch
Visual door interlock switch check

Check that the interlock switch operates smoothly by opening and closing the left ---
hand maintenance door.
Attention! If the insertion key (3) at the door interlock is incorrectly aligned, inad-
vertent shutdown of the compressor package can occur.
The insertion key (3) aligns with the door interlock switch (1) without
binding against the sides of the interlock switch when the maintenance
door is closed.
If necessary, re---align the insertion key (3).

Loosen the bolts (4).
Align the insertion dey (3) so that it glides smoothly into the interlock switch (1).
If necessary, use washers to help align the insertion key (3) with the interlock
switch (1).
Tighten the bolts (4) again.
7 --- 24
Initial Start
6
2
2
3
4
4
1 Door interlock switch 4 Bolt

2 Clamping nut 5 Frame
3 Insertion key 6 Maintenance door
Functional check of the interlock switch
Attention! A functional check of the door interlock switch must be made after in-
itial start.
Start the compressor package (see chapter 8.4).

Open the left ---hand maintenance door --- the compressor package will shut down im-
mediately if the door interlock switch functions correctly.
Close the left ---hand maintenance door.
Reset the alarm message by pressing the acknowledge (reset) key (11, see
chapter 8.3.1) on SIGMA CONTROL.
The compressor package is now ready to start again.
7.6 Motor Overload Relay Adjustment and Changing

Lock the main disconnect in the “off” position in accordance with ap-
§ 910.147) to ensure that the compressor does not restart. See chap-
ter 2.3 for the main disconnect switch.
Attention! The power supply voltage (see circuit diagram) must be fitted and con-
nected with the compatible motor overload relay, and the set point
must be adjusted.
The relay is set to the standard adjustment at the factory.

Compressor motor: Wye -- delta start
Overload relays set points see wiring diagram.
In the Wye---delta configuration the phase current is fed through the motor overload relay.
This phase current is 0.58 times the nominal motor current.
For the nominal motor current see motor nameplate.
7 --- 25
Initial Start
Adjustment:
To prevent the overload relay from tripping (because of voltage fluctuations, temperature
influences or component tolerances), the value can be set up to 15% higher than the
calculated phase current.
Attention! If the power supply voltage is changed, the jumpers inside the motor
terminal box, the motor overload relay and the cutout in the control
cabinet must be changed.
Motor terminal block Motor terminal block
Low voltage High voltage

230V 460V
U6 V6 W6 U6 V6 W6
U2 V2 W2 U2 V2 W2
Jumper
U5 V5 W5
U5 V5 W5
U1 V1 W1 U1 V1 W1
4
3
1 Motor overload (rated power supply)

2 Motor overload (alternative power supply)
3 Reset button
4 Motor overload adjustment
7 --- 26
Initial Start
7.7 Setting the Air System Pressure

The air system pressure is preset at the factory. It can be changed in SIGMA CONTROL to
match customer’s operational requirements if the password is known. For further details,
consult the SIGMA CONTROL service manual.
7 --- 27
Operation
8 Operation
8.1 Control Panel
1 SIGMA CONTROL
2 EMERGENCY STOP pushbutton
8.2 SIGMA controller

The SIGMA controller (1) is fitted in the control cabinet in the compressor package and
serves as the control panel. It has 11 keys and 9 LEDs. Operation of the compressor pack-
age is determined by the settings programmed into the controller.
Further details on individual function keys, LEDs and plain text display relating to possible
alarms and service messages, display of events, etc. are given in the service manual sup-
plied for the SIGMA CONTROL controller.
8.3 Emergency Stop Pushbutton

The Emergency Stop pushbutton shuts down the compressor package immediately.
If the Emergency Stop pushbutton is pressed because of an existing hazard, then this
must be eliminated before the compressor package is reset. To accomplish this the follow-
ing procedure must be carried out:
Unlatch the Emergency Stop pushbutton by turning in the direction of the arrows.
Acknowledge the alarm message on the controller by pressing the acknowledge
(reset) key. (function keys see chapter 8.3.1.)
8 --- 28
Operation
8.3.1 Function keys
7
11 8
10 9
6
1
5 2
4 3
1 ON key (“I”) 6 Menu scroll --- DOWN key
2 OFF key (“0”) 7 Menu scroll --- UP key
3 Timer ON/OFF key 8 Escape key
4 Remote ON key 9 Return key
5 Load/idle key 10 Info --- event key
11 Acknowledge (reset) key
8.3.2 Light emitting diodes and plain text display
13
14 12
15
16 19
17
18
20 21
12 Four ---line display 17 Load LED
13 Alarm LED 18 Idle LED
14 Communication alarm LED 19 Compressor ON LED
15 Warning --- maintenance LED 20 Remote ON LED
16 Power ON LED (to controller) 21 Timer ON LED
8 --- 29
Operation
8.4 Starting and Stopping the Compressor Unit

Attention! Do not start and stop the compressor package with the main discon-
nect switch. The compressor must always be switched ON and OFF
with keys (1) and (2).
To turn the compressor ON (local):

Switch on the main disconnect switch.
The controller carries out a self---test. The self---test sequence is visible in the display (12).
Afterwards, the green LED (16) illuminates permanently.
Press the ON key (1)--- LED (19) illuminates.
The compressor status is indicated by LEDs (17) and (18):
Attention! If LED (19) is illuminated and both LEDs (17) and (18) are extinguished
the compressor package is at standstill but on duty.
The compressor package can start at any moment.
To turn the compressor OFF (local):

Press the OFF key (2) --- LED (19) extinguishes.
Lock the main disconnect in the ”off” position in accordance with applicable lock out/
tag out procedures (example: OSHA CFR 29 § 1910.147) to ensure the compressor
does not restart.
See chapter 2.3 for the main disconnect switch.
8.5 Acknowledgement of Alarms

If an alarm occurs the compressor package is shut down immediately and the red
LED (13) on SIGMA CONTROL flashes.
The bottom line in the display (12) shows the actual fault causing the alarm.
A list of alarms that may occur during operation is included in the SIGMA CONTROL
service manual.
Remove the fault.
Acknowledge alarm with the reset key (11) --- LED (13) extinguishes.
The compressor package is now ready to start again.
Attention! If the compressor was shut down with the EMERGENCY STOP push-
button, then reset by rotating the latched pushbutton in the direction of
the arrow before acknowledging the alarm.
8 --- 30
Operation
8.6 Acknowledgement of Service Messages

When maintenance is due the yellow LED (15) on SIGMA CONTROL flashes.
Attention! Before any maintenance is due an initial warning is displayed to allow

coordination of service and maintenance personnel and provision of
necessary servicing materials. (lubricants, spare parts, etc.).
Maintenance due is shown in the display (12).

A list of service messages that may occur during operation is included in the SIGMA
CONTROL service manual.
Carry out the maintenance work.
Acknowledge service message with the reset key (11) --- LED (15) extinguishes.
Attention! When the respective maintenance has been carried out, the remaining
interval period (programmed interval until the next maintenance is due)
must be reset.
Detailed information on resetting service counters is to be found in the service manual for
SIGMA CONTROL.
8 --- 31
Maintenance
9 Maintenance
9.1 Observe the following rules during all maintenance and servicing work:
Work on power driven equipment may only be carried out by trained or
specialized personnel. Follow all applicable OSHA and local safety
regulations.
If a power failure occurs, the compressor package starts again auto-

matically (normal setting) provided the line pressure is lower than the
pressure threshold parameter entered in SIGMA CONTROL.
Lock the main disconnect switch in the ”off” position in accordance

with applicable lock out/tag out procedures to ensure the compressor
does not restart (see chapter 2.3 for main disconnect switch).
Ensure that no maintenance personnel is working on the compressor

unit, that all panels are latched back on again and all maintenance
doors are closed before restarting the compressor unit.
To start the compressor unit see chapter 8.4).
Attention! The venting nozzle required to vent the oil separator tank (for mainten-
ance work such as topping up the oil, oil change and filter change) is
fitted to the hose coupling (3, see chapter 9.10).
Carry out a visual and functional check of the door interlock switch
after any maintenance and servicing work.
See chapter 7.5 for details.
The following points must be observed when handling lubricating and

cooling materials:
Avoid contact with skin and eyes.

Do not inhale vapors and oil mist.
Do not eat or drink when handling such materials.
Fire, open flame and smoking are strictly forbidden.
Ensure that all lubricants, consumable materials and replacement

parts accumulating during operation and servicing of the compressor
package are disposed of according to environmental regulations.
9 --- 32
Maintenance
9.2 Regular Maintenance
Interval Work to be done See chapter
2 and 24 h after initial Check the v---belt tension 9.4

start
50 h after initial start Check all electrical connections for tightness

and tighten if necessary
200 h after initial start Replace the run ---in oil filter 9.11
Weekly Check the oil level 9.12
Check the filter mats for contamination 9.6
500 h Check the v---belt tension 9.4
Clean or replace the air filter* 9.7
1000 h Check the oil cooler and air aftercooler for con- 9.13
tamination
Clean or replace the filter mats* 9.6
1000 to 2000 h Replace the oil filter* * 9.11
Proper interval varies. Change the oil* 9.14

See chapter 1.8
2000 to 3000 h* * Change the oil separator cartridge* 9.15
Annually Check all electrical connections for tightness

and tighten if necessary
Have the safety relief valve checked by 9.9

authorized KAESER distributor
6000/12000 hours or at Have the compressor motor bearings relubrica- 9.8

least within three years ted by authorized KAESER distributors*
* The maintenance period can vary depending on the cycle rate and environmental
conditions.
* * Not to exceed 2000 service hours.
We urgently recommend that a record is kept of the maintenance work done (see chap-
ter 9.16).
9 --- 33
Maintenance
9.3 Opening and Closing the Compressor Package

To open:
Open the maintenance door (1).
Move the lever (A) in the direction of the arrow and lift up the maintenance door (2).
Loosen the screws (B) and remove the panel (3).
To close:
Close the panel (3) the maintenance door (2) and the maintenance door (1) in the re-
verse order.
Close all maintenance doors and panels correctly before starting the
compressor package.
A B
3
1
B
1 Maintenance door
2 Maintenance door
3 Cover panel
9 --- 34
Maintenance
9.4 Checking the Drive Belt Tension

Switch off the compressor unit (see chapter 8.4).

does not restart.
Check the tension of the belt drive after the first 2 and 24 hours of operation and thereafter
every 500 hours of operation.
2
1
1 Hexagonal nut
2 Hexagonal nut
3 Indicator pin
The belt drive tension is automatically adjusted within a limited range by the pressure
spring of the belt tensioning device.
Re---tension the belt drive if the belts have stretched to the point where the indicator pin (3)
is situated at the top end of its indicator slot.
Loosen the hexagonal nut (2).
Tension the belt drive with the hexagonal nut (1) until the indicator pin (3) is situated at
the bottom end of its indicating slot.
Tighten the hexagonal nut (2).
9.5 Drive Belt Change


with applicable lockout/tagout procedures to ensure the compressor
does not restart.
Loosen the hexagonal nut (2, see chapter 9.4).

Screw the hexagonal nut (1, see chapter 9.4) until the V---belts are loose.
Remove the V---belts.
9 --- 35
Maintenance
Attention! It is essential that replacement belts are all precisely the same length
(each set) and absolutely oil -- proof. For this reason we recommend
that only original KAESER drive belts are used.
Place the new V---belts over the motor and compressor pulleys without straining them.
Set the belt drive tension (see chapter 9.4).
Attention! Check the belt drive tension after 2 hours of operation and then again
after 24 hours of operation, as experience shows that the belts stretch
mostly during this period.
9.6 Cleaning or Replacing the Filter Mat

Clean the filter mat every week depending on the dust content of the intake air and replace
if necessary as detailed in the maintenance schedule (see chapter 9.2).
Switch off the compressor package (see chapter 8.4).

with applicable lockout/tagout procedures to ensure the compressor
does not restart.
1 3 1
2
3
2
2
3 A B
1 Filter
2 Holding frame
3 Closure
Removing version A
Press closures (3) inwards and remove the holding frame.
Removing version B
Open the snap fasteners (turn the flat ---head screw with a screwdriver counter clock-
wise 90) and remove the holding frame.
Cleaning:
Rinse the mat in warm water ( approximately 105F), if necessary, use a mild detergent
soap to rinse out oily dust. The mat can also be tapped, vacuum cleaned or blown out with
compressed air (not in excess of 30 psig).
Attention! If the mat is heavily soiled or has been cleaned often (maximum five
times), replace it.
9 --- 36
Maintenance
Installing version A
Locate the holding frame and press into position.
The holding frame is secure when the closures engage.
Installing version B
Fit the holding frame and close the snap fasteners (turn the flat ---head screw with a
screwdriver clockwise 90 then press until the fasteners snap in).
9.7 Cleaning or Replacing the Air Filter

Clean the air filter after every 500 service hours.
Stop the compressor package (see chapter 8.4).

package does not restart.
1 3
1 Air filter
2 Air filter cap
3 Wing nut for opening air filter housing
4 Air filter cartridge
To open the air filter housing:

Unscrew the wing nut (3) and remove the air filter cap (2) and the filter cartridge (4).
Clean the air filter cap and sealing surfaces.
Cleaning the air filter cartridge (4) by tapping:
Tap the air filter cartridge several times on the front with the ball of the hand.
Attention! Do not use excessive force otherwise the air filter cartridge may be
damaged.
Clean all sealing surfaces.

Cleaning the air filter cartridge with compressed air:
Use dry, compressed air blowing at a pressure of not more than 30 psig at a slant
from the inside to the outside of the air filter cartridge surfaces.
Attention! Do not clean the air filter cartridge with fluids. If the air filter cartridge
is heavily contaminated or was already cleaned several times (max.
five times), replace.
Compressed air shall not be used for cleaning purposes except where
reduced to less than 30 psig and then only with effective chip guarding
and personal protective equipment. (OSHA CFR 29 § 1910.242)
9 --- 37
Maintenance
To close the filter housing:

Insert the filter cartridge (4) and replace the air filter cap (2).
Screw on the wing nut (3) tightly.
9.8 Servicing the Electric Motor

Compressor motor:
The electrical motor bearings are permanently greased.
Attention! Have the motor bearings replaced by authorized KAESER distributors

in accordance with the maintenance schedule (see chapter 1.9).
9 --- 38
Maintenance
9.9 Testing the Safety Relief Valve on the Oil Separator Tank
To test the set point of the safety relief valve, the compressor must be run so that its dis-
charge pressure exceeds the maximum pressure set on the SIGMA CONTROL.
See chapter 1.5 for the safety relief valve activating pressure.
Attention! Have the safety relief valve tested by an authorized KAESER distribu-
tor in accordance with the maintenance schedule (see chapter 9.2).
For more details see SIGMA CONTROL manual.
9.10 Venting the compressor unit

plicable lock out/tag out procedures to ensure the compressor does
not restart.
Lock the isolation shut-- off valve in the ”closed” position and vent all
compressed air trapped between the compressor and the isolation
shut-- off valve in accordance with applicable lock out/ tag out pro-
cedures.
The oil circulation system of the compressor package vents automatically.

Venting the oil separator tank:
11
3
A
2
B 4
5
9
10
8
1 Ball valve 4 Filler plug 8 Minimum oil level

A shut (oil top --- up) 9 Ball valve --- oil drain
B open 5 Oil separator tank 10 Oil drain hose
2 Pressure gauge 6 Nozzle 11 External pressurization
3 Hose coupling 7 Maximum oil level
9 --- 39
Maintenance
The pressure gauge on the oil separator tank must indicate zero psig.
Oil mist can escape when the oil separator tank is vented.
Insert the nozzle (6) in the hose coupling (3) on the oil separator tank. The residual
pressure in the oil separator tank escapes.
Remove the nozzle (6) from the hose coupling (3).
Venting the air aftercooler:
When the compressor package is vented, pressure is still present in

the air aftercooler and the pipework up to the minimum pressure check
valve. For this reason the compressor package must be isolated from
the compressed air system by closing the shut-- off valve between the
compressor package and the compressed air system. If isolation
shut-- off valve is not available, vent the compressed air system com-
pletely.
Carefully remove the screw fitting (4, see chapter 9.13). The air aftercooler vents.
Tighten the screw fitting again.
compressor package.
9.11 Oil Filter Change
Hot oil; beware of scalding.
Attention! Replace the run-- in oil filter cartridge with a standard oil filter cartridge
(supplied with the compressor) after approximately 200 operating
hours.
Change the oil fillter cartridge according to the regular maintenance schedule (see
chapter 9.2) or when the corresponding service message is displayed on SIGMA CON-
TROL (see chapter 8.1).
It is recommended that the oil filter cartridge is replaced always when the oil is changed.
9.11.1 Removal and replacement of the oil filter cartridge

Stop the compressor package under full load (see chapter 8.4).
Before opening or removing pressurized components (pipes, hoses,

tanks, etc.) it is imperative that the compressor package is completely
depressurized.
Venting the compressor package (see chapter 9.10).
9 --- 40
Maintenance
1 Oil filter cartridge

2 Turn in this direction to unscrew the cartridge
Twist the used or contaminated oil filter cartridge counter clockwise to remove and
catch escaping oil in a suitable container.
Dispose of the old oil filter and any used, accumulated oil according to
environmental care regulations!
Clean the face of the combination block with a lint free cloth.
Lightly oil the gasket of the new filter cartridge before screwing into position.
Screw in the new filter cartridge clockwise by hand until the gasket fits tightly.
Attention! Do not use a tool as this may cause damage to the oil filter cartridge
and the gasket.
Check the oil level (see chapter 9.12).

system.
Perform a test run
When the operating temperature is reached (see chapter 1.1), shut

down the compressor package (see chapter 8.4) and lock the main
disconnect in the ”off” position in accordance with applicable lock out/
tag out procedures (example: OSHA CFR 29 § 1910.147) to ensure the
compressor does not restart.
Afterwards, carry out a visual check for leaks.
9.12 Oil Top ---Off

Check the oil level weekly through the oil sight glass when the compressor is shut down. If
necessary, top off the oil to the maximum level. Do not exceed the maximum level (center
of the top oil sight glass).

depressurized.
9 --- 41
Maintenance

11
3
A
2
B 4
5
9
10
8

Unscrew the oil filler plug (4) on the oil separator tank.
Top off the oil to the maximum mark.
Check the gasket ring of the filler plug (4) for damage and then screw in the filler plug.
system.
Attention! After an oil change or oil cooler cleaning (with removal of the oil
cooler) run the compressor package up to operating temperature to
ensure that the combination valve closes and that the oil cooler is
flooded with oil.
Afterwards, repeat the procedures ‘‘Venting the Compressor Package’’

(chapter 9.10) and “Topping off the Oil”
(chapter 9.12).
Attention! Always use the same brand and type of oil when topping off the oil.
(see label on the oil separator tank).
During an oil change, drain the old oil completely and always replace
the oil filter.
Never mix different oil types or brands.
Oil recommendations see chapter 1.8
9 --- 42
Maintenance
9.13 Cleaning the Oil Cooler and Aftercooler

The oil cooler and air aftercooler must be checked for clogging regularly. Heavy contami-
nation could lead to excessive temperatures in the oil circulation system.
See regular maintenance schedule for cooler maintenance interval (chapter 9.2).
Switch off the compressor package under full load (see chapter 8.4).
not restart.

depressurized.
9.13.1 Removing and cleaning the oil cooler/air aftercooler
2
4
1 Allen screw
2 Hose screw fitting
3 Pipe screw fitting
4 Pipe screw fitting
Unscrew the hose connector (2) and the pipe connector (3) from the combination
valve.
Unscrew the Allen screws (1) on the aftercooler.
Remove and check the O---ring on the aftercooler.
Close up the pipes and openings on the combination valve, and aftercooler.
9 --- 43
Maintenance
5 Hexagonal nut
6 Allen screw
Unscrew the hex bolt (5).

The hex socket head bolts (6) are located behind two protective caps.
Attention! Before unscrewing the two hex socket head bolts (6) prop up the com-
bination oil/air aftercooler.
Remove the protective caps and unscrew the two hex socket head bolts (6).
Take out the aftercooler.
Do not direct compressed air, water or steam jets toward any person.
These represent contained energy and as such, are dangerous to life.
The soiled cooler laminations may be cleaned with water or steam jet
only in designated cleaning areas with oil separators suited for such
purpose!
Clean the cooler laminations with compressed air, water or steam jet.
Attention! Seat the O -- rings correctly in the compressed air inlet of the oil/air
aftercooler during reassembly.
Reassemble in the reverse order.

See chapter 9.12 for topping off the oil.
system.
Perform a test run

9 --- 44
Maintenance
9.14 Oil Change (Oil Separator Tank and Oil Cooler)

For type of oil and frequency of oil change see chapter 1.8
Oil change must be carried out with warm to the touch condition of the compressor pack-
age (Oil temperature approx. 104F).
Danger of scalding with hot oil.
When inserting the maintenance hose into the compressor’s hose

couplings, always have the ball valve closed and the hose end se-
cured before slowly opening the ball valve. Beware of air/oil mist that
could blow out of the hose. Unrestricted air/oil flow through the hose
end will result in a whipping action which could cause severe injury or
death.
If the compressor package operates in ambient temperatures close to the maximum ambi-
ent temperature (see chapter 1.6), change the oil more often (e.g. 1/2 or 1/4 of recom-
mended interval).
Attention! Drain the oil out of the oil separator tank, cooler and the oil pipes com-
pletely. See chapter 9.14.4 for putting back into operation.
Attention! If a heat recovery system is fitted drain all the oil in the heat exchanger
during the oil change.
9 --- 45
Maintenance
11
3
A
2
B 4
5
9
10
8


depressurized.
9.14.1 Oil change using external pressure source

Close the ball valve (1).
Insert the nozzle (6) in the hose coupling (3) on the oil separator tank (5).
Connect the nozzle to external pressure source. Pressurize the oil separator tank (5)
until the pressure gauge (2) on the oil separator tank (5) shows approximately
43.5 psig.
Remove the nozzle (6) from the hose coupling (3) on the oil separator tank (5).
Drain the oil from the oil separator tank:
Prepare a clean container to catch escaping oil.
Attention! The container must be large enough to hold the total oil content of the
compressor unit (see chapter 1.7).
Hang the oil drain hose (10) into the container and secure.
Slowly open the ball valve (9). The remaining pressure in the oil circulation forces out
the oil. When air escapes, close the ball valve (9) immediately.
9 --- 46
Maintenance

depressurized.

Drain the oil from the oil cooler:
Prepare an oil container to catch the escaping oil.
Slowly unscrew the oil drain plug (1). The oil drains under the force of gravity.
Screw the oil drain plug (1) back in tightly.
Dispose of the old oil according to environmental regulations.
1
1 Oil drain plug (oil cooler)
9.14.2 Oil top -- off

Unscrew the oil filler plug (4) on the oil separator tank.
Attention! Always use the same brand and type of oil when topping off the oil.
(see label on the oil separator tank).
During an oil change, drain the old oil completely and always replace
the oil filter.
Never mix different oil types or brands.
Oil recommendations see chapter 1.8
Top off the oil to the maximum mark.

See chapter 1.7 for the quantity of oil.
Check the gasket ring of the filler plug (4) for damage and then screw in the filler plug.
9 --- 47
Maintenance
9.14.3 Draining the oil using own compressed air

Shut down the compressor unit under full load (see chapter 8.4).
not restart.
Lock the isolation shut-- off valve in the ”closed” position and vent all
compressed air trapped between the compressor and the isolation
shut-- off valve in accordance with applicable lock out/ tag out proce-
dures.
The compressor unit oil circulation system vents automatically.

The pressure gauge on the oil separator tank must indicate zero psig.
Close the vent line ball valve (1).
compressor package.
Start the compressor package (see chapter 8.4) and allow to run for approximately 30
seconds.
Check the actual pressure on the pressure gauge (2). Open the shut ---off valve (1), let
the pressure on the pressure gauge (2) sink to approximately 40 psig and then close
the shut ---off valve (1) again.
Drain the oil from the oil separator tank and the oil cooler. Proceed as detailed in chap-
ter 9.14.1).
Open the shut ---off valve (1).
Top off the oil. Proceed as detailed in chapter 9.14.2).
9.14.4 Procedure for putting back into operation

Refer to chapter 7.4.1 and follow the instructions in section ‘‘Pouring a small quantity
of oil into the air inlet port” .
Refer to chapter 7.4.2 and followthe instructions in section ”Running the compressor
package in idle”.
Refer to chapter 9.10 and follow the instructions in section ‘‘Venting the compressor
package”.
Top off with oil again (see chapter 9.14.2).
Open the shut ---off valve between the compressor package and the air system.
Start the compressor package (see chapter 8.4) and run until working temperature is
reached (see chapter 1.1).
Top off the oil, see chapter 9.12.
9 --- 48
Maintenance
Perform a test run

9.15 Changing the Oil Separator Cartridge

The service life of the oil separator cartridge is strongly influenced by the degree of conta-
mination of inlet air and on strict adherence to the recommended maintenance intervals of
the air and oil filters.
We recommend that the oil separator cartridge is changed with the oil or when the relevant
service message / alarm message is displayed on SIGMA CONTROL (see chapter 8.1).

depressurized.
6
7
4
2 8
3
7
5 6
9
10
11
12
2 Hose coupling 5 Cover 9 O ---Ring

3 Pressure gauge 6 Gasket 10 Gasket
4 Hexagonal nut 7 Staple 11 Dirt trap screen filter
8 Oil separator cartridge 12 Screw fitting with jet
9 --- 49
Maintenance
Do not remove the staples (7) in the gaskets (6).
The metal parts of the oil separator cartridge are electrically conduc-
tive and thus have to be grounded:
The gaskets (6) are supplied with heavy staples to provide an electri-
cal path from the oil separator tank to the frame of the compressor
unit.
Unscrew the hexagonal bolts (4) and remove cover plate (5).
Dispose of the used oil separator cartridge according to environmental

regulations!
Take out the old oil separator cartridge (8) together with the gaskets (6) and
O---ring (9). Dispose of the old parts according to environmental regulations.
Clean the sealing surfaces of the oil separator tank.
Attention! When cleaning the sealing surfaces, make sure that no dirt particles
fall into the oil separator tank.
The oil separator cartridge is a disposable item and cannot be

cleaned.
Insert the new O---ring (9) in the groove in the oil separator tank.
Insert the new oil separator cartridge (8) with new gaskets (6), fit and tighten down the
cover plate (5) with the hexagonal bolts (4).
Replace the screen filter (11) and the gasket (10) when the oil separator cartridge (8)
is replaced.
system.
Perform a test run

9 --- 50
Maintenance
9.16 Maintenance Schedule

Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Date Description of work Operating hours Signature
9 --- 51
Appendix
11 Appendix
11.1 Wiring Diagram
11 --- 53
Appendix
11.2 Trouble shooting: Possible cause ---Remedy

Attention! Do not attempt to carry out any repair until you are certain of its cause.
11.2.1 Airend temperature is too high (greater than 167F-- 200F)
Possible cause: Remedy:

Cooling air inlet or outlet is too close to Situate unit for adequate air flow.
wall or other blockage.
Air intake filter mats are clogged. Clean the mats or replace if necessary.
Ambient temperature is too high. Provide cooler air from other source or
move compressor to a cooler location.
See chapter 1.6.
Ambient temperature too low. Provide warmer air from other source
or move compressor to warmer loca-
tion or add a cabinet heater. See chap-
ter 1.6.
Cooling air supply is inadequate. Provide required amount of ventilation.
If cooling air outlet duct is used it may Consult authorized KAESER distributor
be too narrow or too long. for duct requirements.
On air cooled units the fins of the cool- Clean with compressed air, water or
ers (oil cooler and air aftercooler) are steam injector. See chapter 9.13.
clogged.
On water cooled units the heat ex- Inspect heat exchanger elements.
changer elements may be clogged. Clean or replace as necessary.
Oil level is low. Check oil level and add necessary
amount of recommended oil.
Check dirt trap strainer in oil return line
for possible contamination.
Thermostatic valve is not functioning Check the valve spring and actuating
correctly. piston. Replace defective parts.
Idle pressure is too low for proper oil Check idle pressure at the separator
circulation. tank. If the pressure is low check the
inlet valve. Adjust inlet valve to main-
tain adequate idle pressure.
Wrong oil is used. Drain old oil completely and replace
with recommended type.
Consult authorized KAESER distributor
for other oil types not listed.
Oil filter is clogged. Replace filter.
Airend is defective. Check airend and replace if defective.
11.2.2 Motor overload relay switches the unit off

Overload relay is defective or setting is Check line current and adjust overload
wrong. relay as necessary.
Replace relay if defective.
11 --- 70
Appendix

Motor is running two phase: defective Check input power, check wiring, tigh-
motor or blown fuse. ten any loose connections.
Replace fuse(s) or motor if necessary.
Oil separator cartridge is contamina- Check pressure differential across car-
ted. tridge. Replace cartridge and dirt trap
strainer if necessary.
Motor starts against pressure because Check ball valve in vent line and open
system does not get vented. if it is closed.
Check the diaphragm in the vent valve
and replace if defective.
Check the minimum pressure check
valve. Adjust minimum pressure func-
tion or replace defective parts as ne-
cessary.
Airend is defective. Check airend and replace if defective.
Ambient temperature is above 104F. Provide adequate compressor ventila-
tion.
Defective motor: bad bearings or short Repair or replace motor.
circuit in windings.
11.2.3 Compressor is running but produces no pressure

Airend rotates in wrong direction. Reverse motor polarity.
Inlet valve does not open or opens Check the inlet valve, control valve and
only partially. lines. Replace defective parts as
needed
Vent valve does not close at full load. Check the combined control/vent valve
and control lines. Replace defective
parts as needed.
Minimum pressure check valve is de- Check the valve and replace defective
fective. parts.
Leaks in plant system. Check for open valves, loose connec-
tions, defective tools, etc.
Plant system air, demand exceeds ca- Reduce system demand or install
pacity of compressor additional compressor(s).
Air leak in unit. Tighten loose connections, repair or
replace defective parts as necessary.
Socket is still in the hose coupling at Remove socket from coupling.
the oil separator tank or aftercooler.
Safety relief valve has blown off. See chapter 11.2.5.
Airend is defective. With unit running, slowly and carefully
place hand over air inlet filter casing.
There should be considerable suction.
If not, airend is producing no pressure.
11 --- 71
Appendix
11.2.4 Oil leaks out of air filter

Oil level in separator tank is too high. Drain oil to correct level.
Inlet valve faulty. Find the fault and replace the defective
part.
11.2.5 Full -- load/Idle sequence occurs too frequently (short cycles)

Receiver tank size is too small or there Consult authorized KAESER distributor
is no tank. for recommended tank size.
Diameter of hose connecting the unit Connecting hose diameter should not
to the receiver tank is too small. be smaller than the air discharge pipe
diameter. Install larger hose if neces-
sary.
Minimum pressure check valve leaks. Check the valve and replace defective
parts.
Flow is restricted at discharge. Look for plugged filters, partially
closed valves, frozen pipes or malfunc-
tioning pressure regulators.
11.2.6 Safety relief valve blows off

System does not discharge at idle. Make sure ball valve in vent line is
open. Check the control lines, inlet
valve and combined control/vent valve.
Replace defective parts as needed.
Oil separator cartridge is contamina- Check the cartridge pressure differen-
ted. tial and replace cartridge if necessary.
Minimum pressure check valve does Check the valve for blockage and re-
not open. place defective parts as necessary.
Safety relief valve not properly sized Check blow ---off pressure and com-
for the pressure of the compressor pare to name plate of the compressor.
unit. Replace if necessary.
11.2.7 Oil inside the unit

Socket is still in the hose coupling at Remove the socket from the coupling.
the separator tank.
Safety valve has blown off. See chapter 11.2.5.
Oil is coming out of air filter. See chapter 11.2.4.
Hose coupling on separator tank is Tighten coupling or replace as
loose. needed.
Oil cooler leaks. Replace oil cooler.
11 --- 72
Appendix
11.2.8 Excessive oil consumption

Wrong oil is being used in the unit. Replace with correct oil type.
Consult authorized KAESER distributor
for other oil types not listed.
Oil separator cartridge has ruptured. Check pressure differential and re-
place oil separator cartridge if neces-
sary.
Oil separator cartridge mountings are Tighten mounting bolts.
loose.
Oil level in separator tank is too high. Drain oil to correct level.
Scavenger line is clogged. Inspect dirt trap strainer in scavenger
line. Clean or replace clogged parts as
necessary.
11 --- 73

Service Manual Kaeser SK 19

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SERVICE MANUAL USE

L . . . . . . . . . . . . . . . . . . . . . . . . . . Volt L Cabinet heaters

Serial No.: ...............................................

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

2 Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7

5 Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 12

7 Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 20

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 52

1.1 Compressor Unit

1.2 Noise Level

1.4 Electrical Connection

Mains voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 460 V 3---phase

Select multi-- strand copper core wire at 40C ambient temperature

1.5 Set Point of the Safety Relief Valve

1.6 Installation Requirements

1.7 Oil Capacities

After oil change or after long period of storage

1.8 Oil recommendations

RECOMMENDED KAESER LUBRICANTS

SIGMA DESCRIPTION MAXIMUM RECOMMENDED

First Oil Change Subsequent Oil

M---460 ISO 46 Semi---Synthetic Lubricant 2,000 Hours 4,000 Hours

* Oil changes may need to be more frequent depending on ambient conditions.

SPECIALTY KAESER LUBRICANTS

SIGMA DESCRIPTION MAXIMUM RECOMMENDED

First Oil Change Subsequent Oil

S---680 ISO 68 Synthetic Lubricant 6,000 Hours 8,000 Hours

* Oil changes may need to be more frequent depending on ambient conditions.

ACCEPTABLE NOT RECOMMENDED

Viton Celcon PVC

Attention! Polycarbonate bowls can be etched by any synthetic lubricant.

1.9 Maintenance for the Electrical Motor

1.10 Dimensional Drawing

2.1 Explanation of Symbols and References

Attention! This symbol is placed by text where considerable attention must be

This symbol identifies environmental protection measures.

 This symbol indicates operations to be carried out by the operator or

- This bullet identifies listings.

Explanation of warning labels

Beware of life -- threatening electricity. Do not touch electrical compo-

2.2 General Safety Precautions

Prior to working on electrical systems of the compressor always per-

1. Lock the main disconnect in the ”off” position in accordance with

2. Ensure the package cannot be switched on again

3. Check that no voltage is present

2.3 Electrical Power Supply

Compressor packages must be installed with a lockable main discon-

For fuse and wire recommendations, see chapter 1.4

2.4 Spare Parts

2.5 Compressed Air System

2.6 Environmental Protection

The condensate accumulating during compression must be fed via a

Maintenance materials/wear items/replacement parts

The following points must be observed:

Avoid contact with skin and eyes.

3.1 Proper use of the Compressor

3.2 Improper use

3.3 Compressed Air Treatment

4.1 Transport Instructions

5 Construction and Operation

Select multi-- strand copper core wire at 40C ambient temperature

This symbol indicates operations to be carried out by the operator or

Select multi-- strand copper core wire at 40C ambient temperature

Start the compressor package (see chapter 8.4).