KAESER KOMPRESSOREN CSD 82 User manual

SERVICE MANUAL
Screw Compressor
Model: CSD
No.: 9.5700.02E
Manufacturer:
KAESER KOMPRESSOREN GmbH
96410 Coburg

PO Box 2143

GERMANY

Tel. + 49---(0)9561---6400

Fax + 49---(0)9561---640130
http://www.kaeser.com

Contents
Chapter --- page
i
1 RegardingthisDocument 1---1.....................................
1.1 Handling the Document 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Further Documents 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Copyright 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Symbols and Identifications 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.1 Warning notices 1 --- 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4.2 Miscellaneous notices and symbols 1 --- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 TechnicalSpecification 2---3.......................................
2.1 Weight 2 --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 Temperature 2 --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 Ambient Conditions 2 --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 Pressure 2 --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 Sound Pressure Level 2 --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 Motor and Performance 2 --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.1 Compressor motor: 2 --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6.2 Fan Motor 2 --- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Cooling oil 2 --- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1 Recommended cooling oil 2 --- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2 Cooling Oil Volumes 2 --- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Power supply 2 --- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.1 Power supply 2 --- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8.2 Power supply specifications 2 --- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9 Water cooling (option K2) 2 --- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.1 Design data 2 --- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.2 Cooling Water Quality 2 --- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.10 Internal Heat Recovery (option W2 / W3) 2 --- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 SafetyandResponsibility 3---11.....................................
3.1 Correct Use 3 --- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Incorrect Use 3 --- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 User’s Responsibilities 3 --- 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.4 Safety Devices 3 --- 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5 Hazards 3 --- 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.1 Danger from electric current 3 --- 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.2 Danger from released spring force 3 --- 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.3 Danger from released compressed air 3 --- 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.5.4 Further dangers 3 --- 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.6 Warning Symbols 3 --- 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7 Emergencies 3 --- 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7.1 Fire fighting 3 --- 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.7.2 Cooling oil 3 --- 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.8 Environmental Protection 3 --- 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
Chapter --- page
ii
4 DesignandFunction 4---15..........................................
4.1 Machine Overview 4 --- 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Cabinet 4 --- 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.2 Function 4 --- 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Options 4 --- 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.1 Machine mountings (option H1) 4 --- 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.2 Cooling air filter mats (option K3) 4 --- 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.3 Water cooling (option K2) 4 --- 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2.4 Heat recovery 4 --- 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3 Operating States and Control Modes 4 --- 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.1 Operating states 4 --- 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.2 Tasks of the controller 4 --- 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.3 Control Modes 4 --- 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.3.4 Modulating control (option C1) 4 --- 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.4 Safety Devices 4 --- 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.5 SIGMA CONTROL Keys and Indicators 4 --- 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Installation and Operating Conditions 5 --- 22. . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Ambient Conditions 5 --- 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Installation Conditions 5 --- 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.1 Place of installation and space required 5 --- 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.2 Ventilation 5 --- 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2.3 Operating in a compressed air network 5 --- 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 Installation 6---25..................................................
6.1 Safety 6 --- 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2 Report any Transport Damage 6 --- 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.3 Install the Compressed Air Connection 6 --- 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.4 Electrical Connection 6 --- 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5 Options 6 --- 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.1 Machine fixing (option H1) 6 --- 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.2 Water cooling connection (option K2) 6 --- 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.5.3 Heat recovery system connection 6 --- 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 InitialStart---up 7---29...............................................
7.1 Before Initial Start---up (or Recommissioning) 7 --- 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Check Installation and Operating Conditions 7 --- 29. . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Setting the overload protection cut---out 7 --- 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.4 Motor Protection Switch Setting 7 --- 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.5 Pour Cooling Oil into the Inlet Port 7 --- 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.6 Checking Direction of Rotation 7 --- 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.7 Initial Start---up 7 --- 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.8 Setting Network Pressure 7 --- 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
Chapter --- page
iii
8 Operation 8---32...................................................
8.1 Switching On and Off 8 --- 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.1 Switching on 8 --- 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.2 Automatic restart 8 --- 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1.3 Switching off 8 --- 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Switching Off in an Emergency and Switching On Again 8 --- 33. . . . . . . . . . . . . . . . .
8.3 Remote On and Off Switching 8 --- 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.4 Switching on and off with the Clock 8 --- 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5 Acknowledging and Resetting Warning and Alarm Messages 8 --- 34. . . . . . . . . . . . .
8.5.1 Resetting alarm messages 8 --- 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.5.2 Resetting warning messages 8 --- 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9 Event Recognition and Fault Rectification 9 --- 36. . . . . . . . . . . . . . . . . . . . . .
9.1 Alarms (machine shut---down, red LED blinking) 9 --- 36. . . . . . . . . . . . . . . . . . . . . . . .
9.2 Warning Messages (yellow LED blinking) 9 --- 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Miscellaneous events (faults) 9 --- 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10 Maintenance 10---46.................................................
10.1 Safety 10 --- 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2 Maintenance Schedule 10 --- 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.1 Resetting maintenance interval counters 10 --- 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.2 Regular maintenance work 10 --- 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.3 Oil change intervals 10 --- 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.2.4 Regular service work 10 --- 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3 Cooler Maintenance 10 --- 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.1 Air cooling (option K1) 10 --- 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.2 Filter mat maintenance (option K3) 10 --- 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.3.3 Water cooling maintenance (option K2) 10 --- 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.4 Internal Heat Recovery Maintenance (option W2 / W3) 10 --- 52. . . . . . . . . . . . . . . . . . .
10.5 Air Filter Maintenance. 10 --- 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.6 Filter mat maintenance (control cabinet ventilator) 10 --- 53. . . . . . . . . . . . . . . . . . . . . . .
10.7 Electric motor maintenance 10 --- 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.8 Checking the Coupling 10 --- 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.9 Venting the Machine Manually 10 --- 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.10 Checking and Topping up the Cooling Oil 10 --- 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.10.1 Check cooling oil level. 10 --- 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.10.2 Topping up the cooling oil 10 --- 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.11 Changing the Cooling Oil 10 --- 60. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.12 Oil filter maintenance 10 --- 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.13 Checking the Pressure Relief Valve. 10 --- 64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.14 Changing the Oil Separator Cartridge 10 --- 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.15 Logging Maintenance Work 10 --- 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents
Chapter --- page
iv
11 Spares, Operating Materials, Service 11 --- 68. . . . . . . . . . . . . . . . . . . . . . . . . . .
11.1 Note the nameplate 11 --- 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.2 Ordering Maintenance Parts and Operating Materials 11 --- 68. . . . . . . . . . . . . . . . . . . .
11.3 Maintenance Contract 11 --- 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.4 Service Addresses 11 --- 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11.5 Spare Parts for Service and Repair 11 --- 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12 De---commissioning, Storage and Transport 12 --- 75. . . . . . . . . . . . . . . . . . . .
12.1 De---commissioning 12 --- 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.2 Packing 12 --- 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.3 Storage 12 --- 75. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.4 Transporting 12 --- 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12.5 Disposal 12 --- 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13 Annex 13---77.......................................................
13.1 Conformity 13 --- 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.2 Diagrams and Drawings 13 --- 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.2.1 Pipeline and instrument flow diagram (P&I diagrams) 13 --- 77. . . . . . . . . . . . . . . . . . . .
13.2.2 Pipeline and instrument flow diagram (option C1) 13 --- 83. . . . . . . . . . . . . . . . . . . . . . .
13.2.3 Dimensional drawing 13 --- 89. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13.2.4 Electrical diagram 13 --- 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Directory of Illustrations
Chapter --- page
v
Fig. 1 Cabinet 4 --- 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 2 Air---cooled machine 4 --- 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 3 Cooling air filter mats 4 --- 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 4 Water cooling 4 --- 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 5 Internal heat recovery 4 --- 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 6 SIGMA CONTROL keys 4 --- 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 7 SIGMA CONTROL indicators 4 --- 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 8 Installation recommendation, dimensions [mm] 5 --- 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 9 Compressed Air Connection 6 --- 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 10 Water cooling connection 6 --- 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 11 Heat recovery 6 --- 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 12 Inlet valve oil filling port 7 --- 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 13 Coupling 7 --- 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 14 Switching On and Off 8 --- 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 15 Switching off in an emergency 8 --- 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 16 Acknowledging and Resetting Warning and Alarm Messages 8 --- 34. . . . . . . . . . . . . . .
Fig. 17 Cleaning the cooler 10 --- 50. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 18 Cooler filter mats 10 --- 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 19 Air filter maintenance. 10 --- 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 20 Control cabinet ventilator 10 --- 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 21 Compressor motor maintenance 10 --- 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 22 Checking the Coupling 10 --- 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 23 Ventilate the machine. 10 --- 57. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 24 Check cooling oil level. 10 --- 58. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 25 Topping up the cooling oil 10 --- 59. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 26 Changing the Cooling Oil, Oil Separator Tank 10 --- 60. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 27 Changing the Cooling Oil 10 --- 62. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 28 Changing the Oil Filter 10 --- 63. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 29 Changing the Oil Separator Cartridge 10 --- 65. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 30 Transport by fork truck 12 --- 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fig. 31 Transport by lifting cradle 12 --- 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table Directory
Chapter --- page
vi
Tab. 1 Nameplate 2 --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 2 Options 2 --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 3 Machine weights 2 --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 4 Machine temperatures 2 --- 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 5 Ambient Conditions 2 --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 6 Pressure relief valve setting 2 --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 7 Sound Pressure Level 2 --- 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 8 Compressor motor data 2 --- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 9 Fan motor data (option K1) 2 --- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 10 Fan motor data (option K2) 2 --- 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 11 Recommended cooling oil 2 --- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 12 Cooling oil volumes 2 --- 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 13 Supply 230V/3/50Hz 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 14 Supply 400V/3/50Hz 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 15 Supply 230V/3/60Hz 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 16 Supply 380V/3/60Hz 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 17 Supply 440V/3/60Hz 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 18 Supply 460V/3/60Hz 2 --- 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 19 Water cooling design data:

T= 10 K 2 --- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 20 Water cooling design data:

T= 30 K 2 --- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 21 Cooler specification; water cooling 2 --- 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 22 Cooling Water Quality 2 --- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 23 Water Quality Specification 2 --- 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 24 General specification of the heat exchanger 2 --- 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 25 Flow rate and heat available (option W2) 2 --- 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 26 Flow rate and heat available (option W3) 2 --- 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 27 Inspection schedule for Germany 3 --- 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 28 SIGMA CONTROL keys 4 --- 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 29 SIGMA CONTROL indicators 4 --- 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 30 Ventilation 5 --- 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 31 Checklist, installation conditions 7 --- 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 32 Alarm messages and actions 9 --- 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 33 Warning messages and actions 9 --- 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 34 Miscellaneous events (faults) 9 --- 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 35 Regular maintenance work 10 --- 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 36 Oil change intervals 10 --- 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 37 Regular service work 10 --- 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 38 Maintenance log 10 --- 67. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tab. 39 Machine maintenance parts 11 --- 68. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regarding this Document
1 --- 1
1 Regarding this Document
1.1 Handling the Document
The service manual is part of the machine.

Keep the service manual in a safe place throughout the life of the machine.

Pass the manual on the next owner/user of the machine.

Ensure that all amendments are entered in the manual.

Enter details from the machine nameplate in the table in chapter 2 ’Technical Specifica-
tions’.
1.2 Further Documents
Included with this Service Manual are documents intended to assist in safe and sure oper-
ation of the machine:

certificate of acceptance / operating instructions for the pressure vessel

manufacturer’s declaration or declaration of conformity in accordance with applicable
directives

SIGMA CONTROL Service Manual

Make sure all documents are to hand and their contents understood.
Request the supply of any missing documents from KAESER.
Make sure you give the data from the nameplate.
1.3 Copyright
This service manual is copyright protected. Queries regarding use or duplication of the
documentation should be referred to KAESER. Correct use of information will be fully sup-
ported.
1.4 Symbols and Identifications
1.4.1 Warning notices
Here is a notice warning of danger.
Here are consequences of ignoring the warning notice.
The word ’Danger’ indicates that death or severe injury can result from ig-
noring the notice.

Always read and diligently comply with warning notices.
Danger levels
Warning notices indicate three levels of danger identified by the signal word under the
danger symbol.
Signal word Meaning Consequences of ignoring the warning
DANGER Warns of imminent threa-
tening danger Death or severe injury or serious damage to
the machine is possible
WARNING Warns of possible threate-
ning danger Death or severe injury or serious damage to the machine is possible
CAUTION Warns of a possibly
dangerous situation Light injury or slight damage possible
DANGER

Regarding this Document
1 --- 2
1.4.2 Miscellaneous notices and symbols

Here is a task to be carried out.
This symbol identifies environmental protection measures.
This indicates important information.

Technical Specification
2 --- 3
2 Technical Specification
Model and important technical information is to me found on the machine nameplate.
Please transfer data from the nameplate.
Model
Material no.
Serial no.
Year of manufacture
Rated power
Motor speed
Maximum working pressure
Ambient temperature
Tab. 1 Nameplate
A summary of the included options helps to relate the service manual information to your
machine.
Please enter details of options.
Option Code Exists
Air cooling K1
Water cooling K2
Cooling air filter mat K3
Additional fan for fitted exhaust ducting K4
Machine mountings H1
Prepared for heat recovery W1
Internal heat recovery

T= 25K W2
Internal heat recovery

T= 55K W3
Modulating control C1
Transformer power supply for refrigeration
dryer T2
Tab. 2 Options
2.1 Weight
Maximum weights are shown. Actual weights of individual machines are dependent on
equipment fitted.
CSD 82 CSD 102 CSD 122
Weight [kg] 1300 1350 1400
Tab. 3 Machine weights
2.2 Temperature
CSD 82 CSD 102 CSD 122
Minimum cut---in temperature
[˚C] 3 3 3
Typical airend discharge tem-
perature during operation [˚C] 75 --- 100 75 --- 100 75 --- 100
Max. airend discharge temp.
(automatic shut---down) [˚C] 110 110 110
Tab. 4 Machine temperatures

Technical Specification
2 --- 4
2.3 Ambient Conditions
CSD 82 CSD 102 CSD 122
Maximum elevation [m] 1000 1000 1000
Ambient temperature [˚C] 3 – 45 3 – 45 3 – 45
Inlet air / cooling air tempera-
ture [˚C] 3 – 45 3 – 45 3 – 45
Maximum relative inlet air hu-
midity at 31 ˚C [%] 100 100 100
Maximum relative inlet air hu-
midity at 45 ˚C [%] 50 50 50
* Higher elevation permissible only after consultation with the manufacturer
Tab. 5 Ambient Conditions
2.4 Pressure
See nameplate for maximum working pressure
Maximum working pressure
[bar] Blow---off setting of the pressure relief valve [bar]
CSD 82 CSD 102 CSD 122
8 11,5 11,5 11,5
11 14 14 14
15 16 16 16
Tab. 6 Pressure relief valve setting
2.5 Sound Pressure Level
Operational state

under load at rated speed, rated delivery and rated pressure.
Measuring conditions:

Free---field measurement to CAGI/PNEUROP PN8 NTC 2.3 at 1 m distance
CSD 82 CSD 102 CSD 122
Sound pressure level (50Hz) [dB(A)] 68 69 70
Sound pressure level (60Hz) [dB(A)] 69 70 71
Tab. 7 Sound Pressure Level
2.6 Motor and Performance
2.6.1 Compressor motor:
CSD 82 CSD 102 CSD 122
Rated power [kW] 45 55 75
Rated speed [rpm] (50 Hz) 2965 2965 2978
Rated speed [rpm] (60 Hz) 3568 3568 3580
Enclosure protection IP 55 IP 55 IP 55
* Transfer data from motor nameplate to the table

Technical Specification
2 --- 5
CSD 122CSD 102CSD 82
Motor bearing greasing
[operating hours] 2000 2000 2000
Grease requirement, each bearing
[g]*
* Transfer data from motor nameplate to the table
Tab. 8 Compressor motor data
2.6.2 Fan Motor
Air cooling (option K1)
CSD 82 CSD 102 CSD 122
Rated power [kW] 1,1 1,1 1,1
Rated speed [rpm] (50 Hz) 940 940 940
Rated speed [rpm] (60 Hz) 1120 1120 1120
Enclosure protection IP 54 IP 54 IP 54
Tab. 9 Fan motor data (option K1)
Water cooling (option K2)
CSD 82 CSD 102 CSD 122
Rated power [kW] (50 Hz) 0,12 0,12 0,12
Rated power [kW] (60 Hz) 0,17 0,17 0,17
Rated speed [rpm] (50 Hz) 2500 2500 2500
Rated speed [rpm] (60 Hz) 2700 2700 2700
Enclosure protection IP 54 IP 54 IP 54
Tab. 10 Fan motor data (option K2)
2.7 Cooling oil
Ordering: see ’Spare Parts, Operating Materials, Service’ chapter 11.
2.7.1 Recommended cooling oil
The standard factory filling is SIGMA FLUID PLUS. SIGMA FLUID FGL/FGH is recom-
mended for use in connection with foodstuff.
A sticker showing the type of oil filled is to be found near the oil separator filling port.
SIGMA FLUID PLUS SIGMA FLUID MOL SIGMA FLUID
FGL
   
Description Synthetic oil Mineral oil Synthetic oil
Application: Standard oil for all
applications except in
connection with fo-
odstuffs.
Designed for high
loading and long
operational life.
Standard oil for all
applications except
in connection with
foodstuffs.
Designed for light
loading.
Specially for use in
compressors where the
air comes in direct con-
tact with foodstuff.
Authorization — — USDA H–1, approved for
the manufacture of fo-
odstuff packaging, meat
processing and other
food processing.

Technical Specification
2 --- 6
SIGMA FLUID
FGL
   
SIGMA FLUID MOLSIGMA FLUID PLUS
Viscosity at
40 ˚C 70 mm2/s (DIN 51562---1) 44 mm2/s (DIN 51562---1) 50.7 / 70 mm2/s (D 445; ASTM test)
Viscosity at
100 ˚C 10.6 mm2/s (DIN 51562---1) 6.8 mm2/s (DIN 51562---1) 8.2 / 10.4 mm2/s (D 445; ASTM test)
Flash point 260 ˚C
(DIN ISO 2592) 220 ˚C (DIN ISO 2592) 254 ˚C (D92; ASTM test)
Density at 15 ˚C 843 kg/m3
(DIN 51757) — —
Pour point ---39 ˚C
(DIN ISO 3016) ---33 ˚C (DIN ISO 3016) —
Demulsibility at
54 ˚C 30 min (DIN ISO 6614) — —
Tab. 11 Recommended cooling oil
2.7.2 Cooling Oil Volumes
CSD 82 CSD 102 CSD 122
Total charge [l] 28 28 28
Top---up volume [l]
(minimum --- maximum 4 4 4
Additional volume [l] (option W2) 4,7 4,7 4,7
Additional volume [l] (option W3) 3,8 3,8 3,8
Additional volume [l] (option W1) *
* Input the additional volume corresponding to your heat recovery system.
Tab. 12 Cooling oil volumes
2.8 Power supply
See electrical diagrams in chapter 13.2.4.
2.8.1 Power supply
The machine is designed for an electrical supply in accordance with EN60204---1
(IEC 204---1), section 4.3. In the absence of user---specified alternatives, the limits given in
this standard must be adhered to. It is recommended that the supplier and user confer and
agree on the basis of EN60204---1, annex B.
The machine requires a symmetrical three---phase power supply.
In a symmetrical three---phase supply the phase angles and voltages are all the same.
The machine may only be operated with a neutral point earthed TN or TTthree---phase
supply. An IT supply is not permitted.
2.8.2 Power supply specifications
The following conductor cross---sections (multicore Cu) and fusing (HRC fuse slow blow)
are given according to VDE0100, parts 430 and 523, for ambient temperatures of 30 ˚C. If
other local conditions prevail (high temperature, non---standard cable laying or cable
lengths above > 50 m) the cross---section should be checked and adjusted accordingly.

Technical Specification
2 --- 7
Rated power supply 230V

10%, 3---ph, 50Hz
CSD 82 CSD 102 CSD 122
Pre---fuse [A] 200 224 ---
Supply [mm2] 4 x 95 4 x 120 ---
Consumption [A] 155 189 ---
Tab. 13 Supply 230V/3/50Hz
Rated power supply 400V

10%, 3---ph, 50Hz
CSD 82 CSD 102 CSD 122
Pre---fuse [A] 100 125 160
Supply [mm2] 4 x 35 4 x 50 4 x 70
Consumption [A] 88 108 138
Tab. 14 Supply 400V/3/50Hz
Rated power supply 230V
 10%, 3---ph, 60Hz
CSD 82 CSD 102 CSD 122
Pre---fuse [A] 200 224 ---
Supply [mm2] 4 x 95 4 x 120 ---
Consumption [A] 160 191 ---
Tab. 15 Supply 230V/3/60Hz
Rated power supply 380V

10%, 3---ph, 60Hz
CSD 82 CSD 102 CSD 122
Pre---fuse [A] 125 125 160
Supply [mm2] 4 x 50 4 x 50 4 x 70
Consumption [A] 98 115 147
Tab. 16 Supply 380V/3/60Hz
Rated power supply 440V

10%, 3---ph, 60Hz
CSD 82 CSD 102 CSD 122
Pre---fuse [A] 100 125 160
Supply [mm2] 4 x 35 4 x 50 4 x 70
Consumption [A] 84 102 124
Tab. 17 Supply 440V/3/60Hz
Rated power supply 460V

10%, 3---ph, 60Hz
CSD 82 CSD 102 CSD 122
Pre---fuse [A] 100 125 160
Supply [mm2] 4 x 35 4 x 50 4 x 70
Consumption [A] 81 98 119
Tab. 18 Supply 460V/3/60Hz

Technical Specification
2 --- 8
2.9 Water cooling (option K2)
2.9.1 Design data
Cooling water temperature rise 10 K
CSD 82 CSD 102 CSD 122
Max. permissible discharge tempera-
ture [˚C] 70 70 70
Max. permissible inlet temperature
[˚C] 40 40 40
Cooling water volume [m3/h] 4,4 5,4 6,3
Water pressure drop [bar] 1,2 1,7 2,4
Tab. 19 Water cooling design data:

T= 10 K
Cooling water temperature rise 30 K
CSD 82 CSD 102 CSD 122
Max. permissible discharge tempera-
ture [

C] 70 70 70
Max. permissible inlet temperature
[
 C] 20 20 20
Cooling water volume [m3/h] 1,5 1,8 2,1
Water pressure drop [bar] 0,5 0,5 0,5
Tab. 20 Water cooling design data:

T= 30 K
Cooler specification
Material of manufacture 1.4401
Solder Copper
Maximum working pressure (cooling water
end) [bar] 10
UNsuitable cooling medium Seawater
Consult Kaeser before using cooling water
solutions
Tab. 21 Cooler specification; water cooling
2.9.2 Cooling Water Quality
Measures for cooling water treatment and filtration are essential and must be carried out.
The addresses of companies specialising in the analysis of cooling water and supplying
suitable equipment for the its treatment can be obtained from KAESERon request.
To avoid operating breakdowns from a corroded or clogged cooler, the cooling water must
meet certain minimum requirements:
pH value 7.5 to 9
Hardness [ dH] 4,0---8,5
Chloride (Cl) [mg/l] < 150
Free chlorine gas (Cl2) [mg/l] < 1
Sulphate (SO3) [mg/l] < 1
Dissolved iron (Fe) [mg/l] < 0.2

Technical Specification
2 --- 9
Hydrogen carbonate (HCO3) [mg/l] 70---300
Sulphate (SO4) [mg/l] < 70
HCO3/ SO4> 1
Electrical conductivity [

S/cm] 10---500
Ammonia (NH3) [mg/l] < 2
Dissolved magnesium (Mn) [mg/l] < 0,1
Dissolved aluminium (Al) [mg/l] < 0,2
Nitrate (NO3), dissolved [mg/l] < 100
Hydrogen sulphate (SO2) [mg/l] < 0,05
Free aggressive carbon dioxide (CO2) [mg/l] < 5
Glycol [%] < 50
Solids (particle size) [mm] < 0,1
Alge not permissible
Tab. 22 Cooling Water Quality
2.10 Internal Heat Recovery (option W2 / W3)
A soldered, plate heat exchanger is installed for heat recovery.
Generally water is used as the heat transfer medium. This must conform to the specifica-
tion given below.
The manufacturer should be consulted before another type of heat transfer
medium is used.
Water Quality Specification
pH value 7.5 to 9
Hardness [ dH] 4,0---8,5
Chloride (Cl)* [mg/l] < 150
Free chlorine gass (Cl2) [mg/l] < 1
Sulphate (SO3) [mg/l] < 1
Dissolved iron (Fe) [mg/l] < 0.2
Hydrogen carbonate (HCO3) [mg/l] 70---300
Sulphate (SO4) [mg/l] < 70
HCO3/ SO4> 1
Electrical conductivity [

S/cm] 10---500
Ammonia (NH3) [mg/l] < 2
Dissolved magnesium (Mn) [mg/l] < 0,1
Dissolved aluminium (Al) [mg/l] < 0,2
Nitrate (NO3), dissolved [mg/l] < 100
Hydrogen sulphate (SO2) [mg/l] < 0,05
Free aggressive carbon dioxide (CO2) [mg/l] < 5
Glycol [%] < 50
Solids (particle size) [mm] < 0,1
Alge not permissible
Tab. 23 Water Quality Specification
If the heat transfer medium outlet temperature is to be kept constant, the
user must install an appropriate regulating device.

Technical Specification
2 --- 10
Heat Exchanger Specification
CSD 82 CSD 102 CSD 122
Maximum working pressure of the
heat transfer medium [bar] 10 10 10
Pressure drop [bar] < 0,1 < 0,1 < 0,1
Plate material 1.4401 1.4401 1.4401
Solder Cu Cu Cu
Maximum permissible temperature of
the heat transfer medium [˚C] 100 100 100
Tab. 24 General specification of the heat exchanger
Flow rate and heat capacity by heating from 45 ˚C to 70 ˚C (equivalent to

T= 25 K),
(option W2)
CSD 82 CSD 102 CSD 122
Flow rate [m3/h] 1,39 1,70 2,00
Max. heat capacity available [kW] 40,3 49,4 58,1
Max. heat capacity available [MJ/h] 145 178 209
Max. heat capacity available [kcal/h] 34669 42511 49940
Tab. 25 Flow rate and heat available (option W2)
Flow rate and heat capacity by heating from 15 ˚C to 70 ˚C (equivalent to

T= 55 K),
(option W3)
CSD 82 CSD 102 CSD 122
Flow rate [m3/h] 0,63 0,77 0,91
Max. heat capacity available [kW] 40,3 49,4 58,1
Max. heat capacity available [MJ/h] 145 178 209
Max. heat capacity available [kcal/h] 34669 42511 49940
Tab. 26 Flow rate and heat available (option W3)

Safety and Responsibility
3 --- 11
3 Safety and Responsibility
Disregarding this notice can result in serious injury!
The machine is made to the latest technical safety standards and acknowledged safety
regulations. Nevertheless, risk of injury and death for the user and third parties and dam-
age to the machine and other property can arise from its use.
The machine may only be used: when it is in technically perfect condition; for the purpose
for which it is intended; and when all safety measures as detailed in the service manual are
put into practice.
In particular, any faults relating to safety must be rectified immediately.
3.1 Correct Use
The machine is intended solely for industrial use in generating compressed air. Any other
use is considered incorrect. The manufacturer is not liable for any damages resulting from
such unspecified use or application. The responsibility, in case, lies solely with the user.
Correct use also includes compliance with the data contained in this manual.
The machine may only be used in consideration of the installation conditions.
3.2 Incorrect Use
Untreated compressed air may not be used:

as breathing air,

for any process in which the air can come into contact with foodstuff.
3.3 User’s Responsibilities
Personnel
Allow only specialists or persons who have been trained or instructed on this machine to
carry out work on the machine. This applies particularly for:

installation and initial start---up,

maintenance and service work,

repairs,

inspections.
Allow work to be carried out on electrical equipment only by a qualified electrician or
trained personnel under the supervision of a qualified electrician, and according to electri-
cal engineering regulations.
Ensure that all persons working on the machine have read, understood and observe the
safety---relevant passages in the service manual.
Give clear instructions on reporting faults and damage to the machine.
Observe the relevant regulations during installation, operation, maintenance and repair of
the machine. These are, for example, nationally applied European directives and/or valid
national laws and safety and accident prevention regulations.
Adhere to inspection schedules and accident prevention regulations
The machine is subject to local inspection schedules.

Safety and Responsibility
3 --- 12
Operation in Germany:

Recurring inspections in accordance with VBG 16 --- § 18
The company (user) must ensure that recurring inspections of safety devices on com-
pressors with motor power greater than 0.5 kW are carried out by qualified persons.
Inspection intervals of one year are generally sufficient.

Oil change in accordance with VBG16 --- §17
Oil change as required but at least once a year. The oil need not be changed if analysis
shows it to be still useable.

Inspection schedule in accordance with operating safety regulations and with the
strictest according to §15.
Inspection Schedule Inspecting authority
Installation and equip-
ping before initial start---up approved supervisory board
Internal inspection every 5 years after installation or
the last inspection approved supervisory board
Strength test every 10 years after installation
or the last inspection approved supervisory board
Tab. 27 Inspection schedule for Germany
3.4 Safety Devices
Do not change, bypass or disable safety devices.
Do not remove or obliterate labels and notices.
Ensure that labels and notices are clearly legible.
More information on safety devices is contained in chapter 4 ’Design and Function’, sec-
tion 4.4 ’Safety Devices’.
3.5 Hazards
Fundamentals: observe the accepted safety regulations
Observe safety regulations at all times when working on the machine.
Examples of these are directives and national regulations concerning safety and accident
prevention.
3.5.1 Danger from electric current
Electric shock can kill!
Touching electrically live components can cause serious injury or death.

Isolate completely from the mains supply (all conductors)
(switch off at the main isolator)

Ensure the supply cannot be switched on again (lock off).

Check that no voltage is present.

Only work on electrical components when they are voltage---free.

Work carefully.

Before switching on again ensure that:

no one is working on the machine,

all panels are in place and secured,

all access doors are closed.
DANGER