COMPRESSED AIR UNIT

TAG ITEM SUPPLIER

1U1 COMPRESSED UNIT COMPETENT
 boc. Nr. : 2E7840-002
COMPRESSED AIR UNlT SPECIFICATION SHEET
Customer Nr. :

C o m m e ~ i aIJob: 2E78
Detergent Factory

item service . item serv~ce

1Ul COMPRESSED AIR UNIT

PROCESS DATA
TYPE: SERVICE TYPE: CONTINUOUS' Nr. of RUNNING UNITSJSPARE: 1 I 0 \

PROCESS DATA
Ma&
INLET TEMPERATURE: 'C 26.6 -.
INLET PRESSURE: bar g ATM
OUTLET PRESSURE: bar g 8
AMBIENT HUMIDITY 69%
FLOW RATE (TOTAL):

COMPRESSEDAIR:
OUTLET DEW POINT.
FLOW RATE :
INSTRUMENTAIR
'*OUTLET DEW WINT:
FLOW RATE :

UTILITIES DATA
POWER DATA: 400Vl50 W 3 PHASES + N
COOLING WATER: 25/27*C @ 3'bar g

ORDERING DATA
COMPRESSEDAIR:
OUTLET DEW POINT: 'C
TOTAL FLOW RATE : - Nm3h 600
INSTRUMENT AIR
OUTLET DEW POINT: C
'
FLOW RATE : Nm31h 349
"9TES:
COMPRESSED AIR UNIT WILL INCLUDE THE FOLLOWING E M S :
- - - - -
Nr 1 SCREW W E W R E S S O R Atr CmW, Model DSD 142 9 (ICIIESER Me), E M 1Kl Complete with $ah&valve
- -
Nr 1 COMPRESSEDAIR WATER COOLER (ifwm I.E. 1) suitable lbr481 CfmAir ccdfng. (Ret. Dac; Na BTUAR-046W 1-12 Rev. 0)
- Nr 1 HOLDUP TANK FOR COMPRESSEDAIR (Itsm 1.V.l- V d = 5 m3)in C.S. MOC (internalepoxy mated)
compkte wilh Pmssute Indicator (itemPI 1.Vl) & Seibfy wlve (item PSV LV1) &Auto Drain Valvrt
(Ref. Doc. No. BNAR-0462EIl-12 Rev. 0)
Make requst for spare parts offer: For Nr. Yeam
When ordering make request for Nr. manuals in language, and Nr. in
NOTES: 1) THE PLANT IS LOCATED AT 2'400m ABOVE THE SEA LEVEL (TEMPERATURE: 8.3/26.6'C)
2) refer sheet 2 for more informath on Mderlng
PURCHASING INFORMATION
Manuf.: KAESER Model: DsHvhry: 30102011 R.dA.:
Drder nr: Order date: 23 07 2011 WelgM, Kg: Sz.,AxBxC:

The~wnkndthhdaamsntb~~.dlgltcllRloh~urlAwve~-~pm~aub~W
AIR DRYER MODEL 8 FILTER MODEL CHANGED
200
70

-1E1
 GAUTAM PNEUMATICS PVT. LTD.
GURGAON

TEST CERTIFJCATE

-5 IS TO CE;Rnm LLOWING GAUGES SUPPLIED Y

MESSERS
1

THROUGH OUR DISmDWOR

MESSERS VINOD-GAUTAM SALES
20, CHAWN BAZAR, DELHI- 1 10006
ARE TESTED AS PER IS 3624 FQR ACC-~Y 2% OF F.S.D.
AGAINST
1
YOUR ORDER NO. DATE

DETAILS OF THE GAUGE

-~~~(4h(&~-@v
9

A h - tl PI d
PRESSORS TEST REPORT
 [,I EC DECLARATION OF CONFORMITY
121 PRESSURE EQUIPMENT DIRECTIVE 97123lEC
131Thisis to declare that the design and construction of the below mentioned products, in the version
marketed by us, fulfil the relevant basic safety and health requirements of the pressure equipment directive.
Any modifications made without prior consultation with us will invalidate this declaration!

[4] Designation of model: .................................................

DC 33, DC 50, DC 75, DC 108,................................................................................
DC 133, DC 169, DC 215
"..................

DC 33 (E), DC 50 E (-,)
..........................................................................
"
DC 108 (El, DC 133 (E)
..........................................................................
El..
[51 Material no.: 9sPqsblMtr
.................................................................
15aI
-~202..
serial no.: ......................

[61 Year of constrL/ct~on:..........2,Q.A..4

........... 0045

Pressure eaui~ment:ralvessels, rbl control valves, piping

Schematic drawinq: A 2326, A 2327, A 2328, A 2329, 191 Notified bodv: ~ 1NORD
1 ~Systems GmbH
A 2330, A 2331, A 2332, A 2333, Langemarckstrasse 20
A 2334, A 2335, A 1374, A 1375 D-45141 Essen
[lea] Desiccant Type Compressed Air Dryer
Classification according to Art. 9 of the PED: [lla] Category 111 Module: B + D
I,lcl Certificate no. module B: 04 202 1 440 05 10033
Certificate no. module D: 07 202 2 440 06 30352

[121 In accordance with directive 97123lEC Annex I number 3.2, the following tests were performed:
- Pressure test - Test of equipment
- Leak test
- Construction test

1131 NOfailures were found.

[141 EC directives concerned: [14al EC machine directive (2006142lEG)

[14b] EC low-voltage directive (2006195lEG)
[,4~1 EC EMC (20041108/EG)

Harmonised standards used: EN IS0 12100-112, EN 294, EN 55014, EN 60204-1

EN 60335-1 - ,. _ -
[,GI National standards and technical s~ecificationsused: AD 2000 data sheets .,

[I71 Notes for the user: The operator's manual must be referred t o for purposes of assembly,
commissioning, operation, maintenance and inspecg~g!

Manufacturer: SPX Dehydration & Process Filtration GmbH

Konrad-Zuse-Stral3e 25
D-47445 Moers

Moers
1191 Location ~211signatur;/Cornpany executive
 -----.--a
- LEADER VALVES LIMITED
Read. Office:- 5-3.S-4. Industrial Town. Jalandhar - 144 004 (India)
REF. Pi,O.!Q.A.l 2010/001175 DATED 28-07-2010

PRESSURE TEST / GUARANTEE CERTIFICATE

BM000014 I 40MM 1-112"
RELIEF VALVE
(Descrlptlon as Above)
a
u 15MM 1/2" 6
. - . . 'LEADER' RELIEF VALVE
RIGHT ANGLE PATTERN -- . -- . -- . --
BWONZE(1BR CLAUSE 282(a)(IV) GR.B) -- SPRING
LOADED ENCLOSED DISCHARGE. --
RENEWABLE SEAT. -- RENEWABLE DISC. -- CU-ALLOY

, .*,--- --
, -
TRIM -- INLET EMD:BSP T V E R TO
THREW T'O BS:ZI'--N;W '--

&k
-. ; - c -_-
MAX, 15
FRESSURE-33C PSIG (20.7 BAR) HYD.
- ..., -35
FEMALE BSP PARALLEL
R OR AIR. -- SHELL TEST

1. ..y
IS
--
~~000016
'LEADER'
(Description as Above)
I
RELIEF VALVE -
40MM 1-1/2"

I t
-
BMOOOOO 1
'LEADER'
STRAIGHT PATTERN --
3 50MM
GLOBE STEAM STOP VALVE
. -- . -- . --
- ' '

BRONZE~IBR CLAUSE 282(a)(1v) GR.B) SCREWED IN

' --e-
--
3

BONNET,INSIDE SCREW,RISING STEM RENEWA&LE SEAT. -- --

RENEWABLE DISC. --
SS(ASTM A276 type 410 ) --
SCREWED F E W W P TAPER THREADS TO BS:21 -- N.A
--
-- MAX. BOP 250 PSIG(17.24 BAR) AT 435 0EG.F (225 DEG.C). TESTED TO 500
I I) PSIG(34.5 BAR) HYD.

t
7BR NO. L19348-3%

BM000082
'LEADER' FUSIBLE PLUG
--
. - - . -- . -- . -- BRONZE(1BR CLAUSE 282(a)(IV) GR.B) TWO PIECE DESIGN -- -- . -- -
FUSIBLE ALLOY (MELTING TEMP. 270 Deg. Cent.) -- SCREWED MALE W P TAPER THREADS
TO BS:21 -- N.A -- 250 PSIG (17.24 BKR) STEAM. -- TESTER 500 PSIG(34.5 BAR)
HYD.

1bd NO. L l U 3 5 - 8 3 6
3 B-TECH ENGINEERS
DEALS IN : AIR COMPRESSORS, VACUUM PUMPS
Spl. In : All Types of Air Dryers, Air Receiver, Vacuum Vessel
Heat Exchanger, After Cooler, Air Heater, Filters, Water Chiller
F-3A, Mukhram Garden, Tilak Nagar, New Delhi - 110 018
Tel. : +91 11 25990688, Fax : +91 11 25990785
Mob. : +91 93500 87618,98100 44292
E-mail : info@btechengineers.com, btechengineers@yahoo.com
Website : www.btechengineers.com

4F

HYDRAULIC TEST CERTWICATE

Client : Mfs.S.~mPvt.Ltd./MItsdiaLtd.

-- v.
- , r P . 2 s w
-- ---
IJeYCr( A k w
-----
-Tv&
Client P.O. No.
I:&
-
B-Tech Job No. : 4074/11-12

Equipment. (1 V1)

Drawing No.
Material of C0nstrur;tian
Fluid to be stored
wdrkiq ~ l o ~ u l s

:
-
Hydnutic tort has been done at 15 k% /d
fbr 30 on 08-10-2011 and m- 1
ebsavad during the holdiqg h e .
 ) B-TECH ENGINEERS
DEALS IN : AIR COMPRESSORS, VACUUM PUMPS
Spl. In : All Types of Air Dryers, Air Receiver, Vacuum Vessel
Heat ~xchanger,After cooler, Air Heater, Filters, Water Chiller
F-3A, Mukhram Garden, Tilak Nagar, New Delhi - 110 018
Tel. : +91 11 25990688, Fax : +91 11 25990785
Mob. : +91 93500 87618,98100 44292
E-mail : info@btechengineers.com, btechengineers@yahoo.com
Website : www.btechenaineers.com

------

HYDRAULICTEST CERTfFiCATE
CertEici rtew .-e : BZtE-953
Client :W ~ ~ ~ P v t . M / M i I I o d k L t d .
- +;:'-----
-
-L
LL

&. *./.- %
. EquiQauezlt w a a c . d o d ~ .a ~ -~-9~-
-- k\ A

Clierrt P.O. No. :V d

&Tech Jo6 No. : 407911-12

1. Equipment (1E1)

2. Ori-
3. Capacity
4. Dn*No.

8. D e s i g n ~
9. Hydro test Prersrse
10. Testing Medium

I.

~ - ~ - * ~ ~ t a ~ ~ d o k . t 1 6 . 5 ~ ~ 2 ~ 3 0adnoleakwe
~ m 1 0 - 1 0 -
obsauad.dmiq t
k W i g time.
 -
---.
LEADER VALVES LIMITED
Read. Office:- 5 - 3 . S-4. I n d u s t r i a l T o w n . Jalandhar - 144 004 ( I n d i a )

REF-. NO.!Q.A./ 2010/001175 DATED 28-07-2010

r'

PRESSURE TEST / GUARANTEE CERTIFICATE

&
C m BM000014 I 40MM 1-112" 2
'LEADER' RELIEF VALVE
(Description as Above)

I I

PTC

'LEADER' RELIEF VALVE

RIGHT ANGLE PAlTERN -- -- -- . . . --
BRONZE(IBR CLAUSE 282(a)(IV) GR.6) -- SPRING
LOADED ENCLOSED DISCHARGE. -- RENEWABLE S A T . --
RENEWABLE DISC. -- CU-ALLOY
TRIM -- INLET EMD:BSP TAPPER TO BS:21 0UTm:SCREWED FEMALE BSP PARALLEL
THREAD TO €95:2 1 -- N.A --
MA& 130 P S B (10.34 BAA) WATER OR ATR. -- SHELL TEST
PRESSURE-30C PSfG (20.7 BAR) HYD.
t 4 p - r .F- - 7:"-.- --
i I
2.

PTC

15
'LEADER'
BM000016

(Description as Above)
I
RELIEF VALVE
-
40MM 1-112"

- & ,

&sa
BMOOOOO 1 3 50MM
'LEADER' GLOBE STEAM STOP VALVE
STRAIGHT PATTERN -- . -- . -- . --
BRONZE(IBR CLAUSE 282(a)(IV) GR.6) SCREWED IN --
--
BONNET,INSIDE SCREW,RISING STEM R E N E W L E SEAT. -- RENEWABLE DISC. --
SS(ASTM A276 type 410 ) -- SCREWED FEWlE BSP TAPER THREADS TO BS: 2 1 N.A --
-- MAX. BOP 250 PSIG(17.24 WR) AT 435 0EG.F (225 DEG.C). TESTED TO 500 --
SIG(34.5 BAR) HYD. -
q

.- I
R NO. L19348-3513
- -- -

9 BM000082 D 15MM 112"

'LEADER' FUSIBLE PLUG
. - - . -- . -- . --
BRONZE(1BR CLAUSE 282(a)(IV) GR.6) --
TWO PIECE DESIGN -- -- - -- .
FUSIBLE ALLOY (MELTING TEMP. 270 Deq. Cent.) --
SCREWED MALE S P TAPER THREADS
TO BS:21 -- N.A -- 250 PSIG (17.24 BAR) STEAM. --
TESTED TO 500 PSIG(34.5 BAR)
HYD.

1bd NO. L16835-836

 -G7, --
ER V A N E S LIMITED h ,\
$1
Raab. Office:- S-3. S-4. Industrial Town. Jalandhar - 144 004 (India) *

DATED 28-07-20lC

RESSURE TEST / GUf4RANTEE CERTIFICATE

uthenticated
For LEADER VALVES LIMITED

Authorised Signat* .
 Service Manual

Screw Compressor

DSD SIGMA CONTROL

9_6977 00 E

Manufacturer:

KAESER KOMPRESSOREN GmbH

96450 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
 Original instructions
/KKW/SDSD 1.00 en SBA-SCHRAUBEN-SC
 Contents

1 Regarding this document

1.1 Using the Document ......................................................................................................... 1
1.2 Further documents ........................................................................................................... 1
1.3 Copyright .......................................................................................................................... 1
1.4 Symbols and Identification ............................................................................................... 1
1.4.1 Warnings ............................................................................................................. 1
1.4.2 Other instructions and symbols .......................................................................... 2
2 Technical Specification
2.1 Nameplate ........................................................................................................................ 3
2.2 Options ............................................................................................................................. 3
2.3 Weight .............................................................................................................................. 4
2.4 Temperature ..................................................................................................................... 4
2.5 Ambient conditions ........................................................................................................... 4
2.6 Ventilation ........................................................................................................................ 5
2.7 Pressure ........................................................................................................................... 5
2.8 Free air delivery ............................................................................................................... 6
2.9 Cooling Oil Recommendation .......................................................................................... 6
2.10 Cooling oil charge ............................................................................................................ 7
2.11 Motors and power ............................................................................................................ 8
2.11.1 Drive motor ......................................................................................................... 8
2.11.2 Fan motor ........................................................................................................... 9
2.11.3 Fan motor ........................................................................................................... 10
2.12 Sound pressure level ....................................................................................................... 11
2.13 Power Supply ................................................................................................................... 11
2.14 Power supply specifications ............................................................................................. 12
2.14.1 Mains frequency: 50 Hz ...................................................................................... 12
2.14.2 Mains frequency: 60 Hz ...................................................................................... 12
2.15 Water-cooling ................................................................................................................... 13
2.15.1 Design data ......................................................................................................... 13
2.15.2 Cooling water quality .......................................................................................... 14
2.16 Heat recovery ................................................................................................................... 15
2.16.1 Prepared for external heat recovery ................................................................... 15
2.16.2 Internal heat recovery ......................................................................................... 15
3 Safety and Responsibility
3.1 Basic Information ............................................................................................................. 18
3.2 Specified Use ................................................................................................................... 18
3.3 Improper Use ................................................................................................................... 18
3.4 User's Responsibilities ..................................................................................................... 18
3.4.1 Observe statutory and universally accepted regulations .................................... 18
3.4.2 Qualified personnel ............................................................................................. 19
3.4.3 Adherence to inspection schedules and accident prevention regulations .......... 19
3.5 Dangers ............................................................................................................................ 20
3.5.1 Safely Dealing with Sources of Danger .............................................................. 20
3.5.2 Safe Machine Operation ..................................................................................... 22
3.5.3 Organisational Measures .................................................................................... 23
3.5.4 Danger Areas ...................................................................................................... 23
3.6 Safety Devices ................................................................................................................. 23
3.7 Safety signs ...................................................................................................................... 24
3.8 In emergency ................................................................................................................... 25
3.8.1 Correct fire fighting ............................................................................................. 25
3.8.2 Remove any cooling oil from your person .......................................................... 25
3.9 Warranty ........................................................................................................................... 26
3.10 Environmental Protection ................................................................................................. 26

Service Manual Screw Compressor

9_6977 00 E DSD SIGMA CONTROL i
 Contents

4 Design and Function

4.1 Enclosure ......................................................................................................................... 27
4.2 Functional Description of the Machine ............................................................................. 27
4.3 Floating relay contacts ..................................................................................................... 28
4.4 Options ............................................................................................................................. 29
4.4.1 Water-cooling ...................................................................................................... 29
4.4.2 Heat recovery ..................................................................................................... 29
4.4.3 Machine mountings ............................................................................................. 30
4.5 Operating modes and control modes ............................................................................... 30
4.5.1 Operating modes ................................................................................................ 30
4.5.2 Control modes .................................................................................................... 31
4.6 Safety devices .................................................................................................................. 32
4.7 SIGMA CONTROL Keys and Indicators .......................................................................... 32
5 Installation and Operating Conditions
5.1 Safety ............................................................................................................................... 35
5.2 Installation Conditions ...................................................................................................... 35
5.2.1 Place of installation and distances ...................................................................... 35
5.2.2 Ensure adequate ventilation. .............................................................................. 36
5.2.3 Exhaust duct design ........................................................................................... 37
5.3 Operating the Machine in an Air System. ......................................................................... 37
6 Installation
6.1 Safety ............................................................................................................................... 38
6.2 Reporting Transport Damage ........................................................................................... 38
6.3 Making the Compressed Air Connection .......................................................................... 38
6.4 Connecting the Power Supply .......................................................................................... 39
6.5 Options ............................................................................................................................. 40
6.5.1 Ânchoring the machine ....................................................................................... 40
6.5.2 Connecting the Cooling Water ............................................................................ 40
6.5.3 Connecting the Heat Recovery System .............................................................. 41
7 Initial Start-up
7.1 Safety ............................................................................................................................... 43
7.2 Instructions to be Observed before before Every Start-Up .............................................. 43
7.3 Checking positioning and operating conditions ................................................................ 44
7.4 Setting the overload protection cut-out ............................................................................ 45
7.5 Setting the motor overload protection switch ................................................................... 45
7.6 Pouring cooling oil into the airend .................................................................................... 45
7.7 Check Direction of Rotation ............................................................................................. 46
7.8 Starting the Machine for the First Time ............................................................................ 47
7.9 Setting the Setpoint Pressure .......................................................................................... 47
7.10 Changing the display language ........................................................................................ 48
8 Operation
8.1 Switching On and Off ....................................................................................................... 49
8.1.1 Switching on ....................................................................................................... 49
8.1.2 Shutdown ............................................................................................................ 49
8.2 Switching Off in an Emergency and Switching On again ................................................. 50
8.3 Remote On and Off Switching .......................................................................................... 50
8.4 Switching On and Off with the Clock ................................................................................ 51
8.5 Acknowledging Alarm and Warning Messages ................................................................ 52
9 Fault Recognition and Rectification
9.1 Basic Information ............................................................................................................. 54
9.2 Alarm messages (machine shut-down) ............................................................................ 54
9.3 Warning messages (yellow LED lights) ............................................................................ 57

Service Manual Screw Compressor

ii DSD SIGMA CONTROL 9_6977 00 E
 Contents

9.4 Other Faults ..................................................................................................................... 61

10 Maintenance
10.1 Safety ............................................................................................................................... 62
10.2 Maintenance Schedule ..................................................................................................... 62
10.2.1 Logging maintenance work ................................................................................. 62
10.2.2 Resetting maintenance interval counters ............................................................ 63
10.2.3 Regular maintenance tasks ................................................................................ 63
10.2.4 Cooling Oil: Change Interval ............................................................................... 64
10.2.5 Regular service tasks ......................................................................................... 64
10.3 Cleaning or Renewing the Cooling Air Filter Mat ............................................................. 65
10.4 Cleaning or Replacing the Control Cabinet Filter Mats .................................................... 66
10.5 Cooler maintenance ......................................................................................................... 67
10.6 Water-cooling Maintenance ............................................................................................. 68
10.7 Heat Recovery System Maintenance ............................................................................... 68
10.7.1 External heat recovery ........................................................................................ 68
10.7.2 Internal heat recovery ......................................................................................... 68
10.8 Change the air filter .......................................................................................................... 69
10.9 Motor maintenance .......................................................................................................... 70
10.10 Checking the coupling ...................................................................................................... 71
10.11 Checking the Pressure Relief Valve ................................................................................. 72
10.12 Checking the Excess Temperature Safety Shutdown Function ....................................... 72
10.13 Checking the cooling oil level ........................................................................................... 73
10.14 Venting the Machine (depressurizing) .............................................................................. 73
10.15 Topping up the Cooling Oil ............................................................................................... 75
10.15.1 Venting the machine (depressurizing) ................................................................ 76
10.15.2 Topping up with cooling oil and trial run ............................................................. 77
10.16 Changing the cooling oil ................................................................................................... 77
10.17 Changing the Oil Filter ..................................................................................................... 81
10.18 Changing the oil separator cartridge ................................................................................ 82
10.19 Assembling flexible pipe connections .............................................................................. 84
10.20 Document maintenance and service work. ...................................................................... 86
11 Spares, Operating Materials, Service
11.1 Note the Nameplate ......................................................................................................... 87
11.2 Ordering consumable parts and operating materials ....................................................... 87
11.3 SIGMA AIR SERVICE ...................................................................................................... 87
11.4 Service Addresses ........................................................................................................... 88
11.5 Spare parts for service and repair .................................................................................... 88
12 Decommissioning, Storage and Transport
12.1 Putting Out of Operation .................................................................................................. 93
12.2 Packing ............................................................................................................................ 93
12.3 Storage ............................................................................................................................. 93
12.4 Transporting ..................................................................................................................... 94
12.4.1 Safety .................................................................................................................. 94
12.4.2 Transporting with a forklift truck .......................................................................... 94
12.4.3 Transporting with a crane ................................................................................... 94
12.5 Disposal ........................................................................................................................... 95
13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram) ....................................................... 96
13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ........... 102
13.3 Dimensional Drawing ....................................................................................................... 108
13.4 Electrical Diagram ............................................................................................................ 112

Service Manual Screw Compressor

9_6977 00 E DSD SIGMA CONTROL iii
 Contents

Service Manual Screw Compressor

iv DSD SIGMA CONTROL 9_6977 00 E
 List of Illustrations

Fig. 1 Maximum relative humidity ......................................................................................................... 5

Fig. 2 Location of safety signs .............................................................................................................. 24
Fig. 3 Enclosure ................................................................................................................................... 27
Fig. 4 Machine layout ........................................................................................................................... 28
Fig. 5 Water-cooling (option K2) ........................................................................................................... 29
Fig. 6 Internal heat recovery (option W2/W3) ....................................................................................... 30
Fig. 7 Machine mountings .................................................................................................................... 30
Fig. 8 Keys ........................................................................................................................................... 32
Fig. 9 Indicators .................................................................................................................................... 33
Fig. 10 Recommended installation and dimensions [mm] ...................................................................... 36
Fig. 11 Compressed air connection ........................................................................................................ 39
Fig. 12 Connecting the cooling water ..................................................................................................... 40
Fig. 13 Connecting the heat recovery system ........................................................................................ 41
Fig. 14 Inlet valve filling port ................................................................................................................... 46
Fig. 15 Coupling ..................................................................................................................................... 46
Fig. 16 Label: Changing the display language ....................................................................................... 48
Fig. 17 Switching on and off ................................................................................................................... 49
Fig. 18 Switching off in an emergency ................................................................................................... 50
Fig. 19 Switching on and off in remote ................................................................................................... 51
Fig. 20 Switching on and off with the clock ............................................................................................ 52
Fig. 21 Acknowledging/resetting messages ........................................................................................... 53
Fig. 22 Cooling air filter mat ................................................................................................................... 65
Fig. 23 Control cabinet ventilation grill ................................................................................................... 66
Fig. 24 Cooler cleaning .......................................................................................................................... 67
Fig. 25 Air filter maintenance .................................................................................................................. 69
Fig. 26 Drive motor maintenance ........................................................................................................... 70
Fig. 27 Checking the coupling ................................................................................................................ 71
Fig. 28 Checking the cooling oil level ..................................................................................................... 73
Fig. 29 Venting the machine ................................................................................................................... 74
Fig. 30 Topping up the Cooling Oil ......................................................................................................... 75
Fig. 31 Changing the cooling oil, oil separator tank ............................................................................... 78
Fig. 32 Changing the cooling oil, oil cooler ............................................................................................. 79
Fig. 33 Changing the cooling oil, airend ................................................................................................. 80
Fig. 34 Changing the cooling oil, heat recovery system ......................................................................... 81
Fig. 35 Changing the oil filter .................................................................................................................. 82
Fig. 36 Changing the oil separator cartridge .......................................................................................... 83
Fig. 37 Assembling flexible pipe connections ......................................................................................... 84
Fig. 38 Transporting with a forklift truck ................................................................................................. 94
Fig. 39 Transporting with a crane ........................................................................................................... 95

Service Manual Screw Compressor

9_6977 00 E DSD SIGMA CONTROL v
 List of Illustrations

Service Manual Screw Compressor

vi DSD SIGMA CONTROL 9_6977 00 E
 List of Tables

Tab. 1 The levels of danger and their meaning ..................................................................................... 2

Tab. 2 Nameplate .................................................................................................................................. 3
Tab. 3 Options ....................................................................................................................................... 3
Tab. 4 Machine weight .......................................................................................................................... 4
Tab. 5 Temperature ............................................................................................................................... 4
Tab. 6 Ambient conditions ..................................................................................................................... 4
Tab. 7 Ventilation ................................................................................................................................... 5
Tab. 8 Pressure relief valve activating pressure (50 Hz) ....................................................................... 5
Tab. 9 Pressure relief valve activating pressure (60Hz) ........................................................................ 6
Tab. 10 FAD (50 Hz) ............................................................................................................................... 6
Tab. 11 FAD (60 Hz) ............................................................................................................................... 6
Tab. 12 Cooling Oil Recommendation ..................................................................................................... 6
Tab. 13 Cooling oil charge (option K1) .................................................................................................... 7
Tab. 14 Cooling oil charge (option K2) .................................................................................................... 7
Tab. 15 Cooling oil charge (option W1) ................................................................................................... 8
Tab. 16 Cooling oil charge (option W2) ................................................................................................... 8
Tab. 17 Cooling oil charge (option W3) ................................................................................................... 8
Tab. 18 Drive motor ................................................................................................................................. 8
Tab. 19 Drive motor rated speed (50 Hz) ................................................................................................ 8
Tab. 20 Drive motor rated speed (60Hz) ................................................................................................. 9
Tab. 21 Fan motor connection 400V/3/50Hz (option K1) ........................................................................ 9
Tab. 22 Fan motor connection 380V/3/60Hz (option K1) ........................................................................ 9
Tab. 23 Fan motor connection 440V/3/60Hz (option K1) ........................................................................ 10
Tab. 24 Fan motor connection 460V/3/60Hz (option K1) ........................................................................ 10
Tab. 25 Fan motor (option K2) ................................................................................................................ 10
Tab. 26 Sound pressure level .................................................................................................................. 11
Tab. 27 Connection details 400V/3/50Hz ................................................................................................ 12
Tab. 28 Connection details 380V/3/60Hz ................................................................................................ 12
Tab. 29 Connection details 440V/3/60Hz ................................................................................................ 13
Tab. 30 Connection details 460V/3/60Hz ................................................................................................ 13
Tab. 31 Cooling water temperature (ΔT=10K) ........................................................................................ 13
Tab. 32 Cooling water temperature (ΔT=30K) ........................................................................................ 13
Tab. 33 Cooler specification (option K2) ................................................................................................. 14
Tab. 34 Cooling water quality .................................................................................................................. 14
Tab. 35 Heat capacity (option W1) .......................................................................................................... 15
Tab. 36 Water quality specification .......................................................................................................... 15
Tab. 37 Heat exchanger specification (option W2/W3) ........................................................................... 16
Tab. 38 Heat capacity (option W2/W3) .................................................................................................... 16
Tab. 39 Flow rate (option W2) ................................................................................................................. 17
Tab. 40 Flow rate (option W3) ................................................................................................................. 17
Tab. 41 Inspection intervals according to Ordinance on Industrial Safety and Health ............................ 20
Tab. 42 Danger Areas ............................................................................................................................. 23
Tab. 43 Safety signs ................................................................................................................................ 24
Tab. 44 Operating modes under MODULATING control ......................................................................... 32
Tab. 45 Keys ........................................................................................................................................... 32
Tab. 46 Indicators .................................................................................................................................... 33
Tab. 47 Initial start-up after storage ......................................................................................................... 44
Tab. 48 Positioning and operating conditions checklist ........................................................................... 44
Tab. 49 Machine identification ................................................................................................................. 51
Tab. 50 Remote control identification ...................................................................................................... 51
Tab. 51 Machine identification ................................................................................................................. 52
Tab. 52 Alarm messages and measures ................................................................................................. 54
Tab. 53 Warning messages ..................................................................................................................... 57
Tab. 54 Other faults and actions ............................................................................................................. 61

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9_6977 00 E DSD SIGMA CONTROL vii
 List of Tables

Tab. 55 Regular maintenance tasks ........................................................................................................ 63

Tab. 56 Cooling oil changing intervals ..................................................................................................... 64
Tab. 57 Regular service tasks ................................................................................................................. 64
Tab. 58 Dimensions of the flexible pipe connection ................................................................................ 85
Tab. 59 Logged maintenance tasks ........................................................................................................ 86
Tab. 60 Consumable parts ...................................................................................................................... 87

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viii DSD SIGMA CONTROL 9_6977 00 E
 1 Regarding this document
1.1 Using the Document

1 Regarding this document

1.1 Using the Document
The service manual is part of the machine. It describes the machine as it was at the time of first
delivery after manufacture.
➤ Keep the service manual in a safe place throughout the life of the machine.
➤ Pass the manual on to the next owner/user of the machine.
➤ Ensure that all amendments received are entered in the manual.
➤ Enter details from the machine nameplate and individual items of equipment in the table in chap‐
ter 2.

1.2 Further documents

Included with this service manual are additional documents intended to assist in the safe operation
of the machine:
■ Certificate of acceptance/operating instructions for the pressure vessel
■ Manufacturer's declaration / declaration of conformity in accordance with applicable directives.
■ Operating instructions for SIGMA CONTROL.

Missing documents can be requested from KAESER.

➤ Make sure all documents are complete and observe the instructions contained in them.
➤ Make sure you give the data from the nameplate when ordering documents.

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 supported.

1.4 Symbols and Identification

1.4.1 Warnings
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION

DANGER
These show the kind of danger and its source!
The possible consequences of ignoring a warning are shown here.
The word "Danger" indicates that death or severe injury can result from ignoring the instruction.
➤ The measures required to protect yourself from danger are shown here.

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9_6977 00 E DSD SIGMA CONTROL 1
 1 Regarding this document
1.4 Symbols and Identification

➤ Always read and comply with warning instructions.

Signal word Meaning Consequences of non-observance

DANGER Warns of an imminent threat of danger Death or serious injury may result
WARNING Warns of possible danger Death or serious injury are possible
CAUTION Warns of a possibly dangerous situa‐ Light injuries or material damage are possible
tion

Tab. 1 The levels of danger and their meaning

1.4.2 Other instructions and symbols

This symbol refers to particularly important information.

Material Here you will find details on special tools, operating materials or spare parts.

Precondition Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.

Option H1 ➤ This bullet is is placed by lists of actions comprising one stage of a task.
In lists of actions with several stages the sequence of actions is numbered.
Information that refers to only one option is marked with an indicator (e.g.: H1 means that this
section is only valid for machines with adjustable machine mountings). Option indicators used in
this service manual are explained in chapter 2.2 .
Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protection.

Further information Here, your attention is drawn to further topics.

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2 DSD SIGMA CONTROL 9_6977 00 E
 2 Technical Specification
2.1 Nameplate

2 Technical Specification
2.1 Nameplate
The model designation and important technical information are given on the machine's nameplate.

The nameplate is located on the outside of the machine:

■ above the cooler,
or
■ on the rear of the machine.

➤ Enter the data from the nameplate here as a reference:

Attribute Data
Model
Material no.
Serial no.
Year of manufacture
Rated power
Motor speed
Maximum working pressure
Ambient temperature

Tab. 2 Nameplate

2.2 Options
The table contains a list of possible options.
➤ Enter options here as a reference

Option Option code Exists?

Modulating control C1
SIGMA CONTROL C3
Machine mountings H1
Air-cooling K1
Water-cooling K2
Cooling-air filter mat K3
Prepared for heat recovery W1
Internal heat recovery system ΔT=25K W2
Internal heat recovery system ΔT=55K W3

Tab. 3 Options

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 2 Technical Specification
2.3 Weight

2.3 Weight
The weight given is the maximum. The actual weights of individual machines are dependent on
equipment fitted.

DSD 142 DSD 172 DSD 202 DSD 238

Weight [kg] 2900 3050 3400 3600

Tab. 4 Machine weight

2.4 Temperature
DSD 142 DSD 172 DSD 202 DSD 238
Minimum cut-in tempera‐ 3 3 3 3
ture [°C]
Typical airend discharge 75–100 75–100 75–100 75–100
temperature during opera‐
tion [°C]
Maximum airend dis‐ 110 110 110 110
charge temperature (auto‐
matic safety shut-down)
[°C]

Tab. 5 Temperature

2.5 Ambient conditions

DSD 142 DSD 172 DSD 202 DSD 238
Maximum altitude AMSL* 1000 1000 1000 1000
[m]
Permissible ambient tem‐ 3–45 3–45 3–45 3–45
perature [°C]
Cooling air temperature 3–45 3–45 3–45 3–45
[°C]
Inlet air temperature [°C] 3–45 3–45 3–45 3–45
Maximum relative humidi‐ see figure 1 see figure 1 see figure 1 see figure 1
ty of inlet air
* Higher altitudes are permissible only after consultation with the manufacturer.

Tab. 6 Ambient conditions

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4 DSD SIGMA CONTROL 9_6977 00 E
 2 Technical Specification
2.6 Ventilation

Fig. 1 Maximum relative humidity

T Inlet air temperature [°C]
H Maximum relative humidity of inlet air [%]

2.6 Ventilation
The values given are minimum guide values.

DSD 142 DSD 172 DSD 202 DSD 238

Inlet aperture Z see fig‐ 1.8/0.3* 2.1/0.3* 2.7/0.4* 3.2/0.5*
ure 10 [m2]
Extractor for forced venti‐ 26000 30000 38000 45000
lation: 4000* 4500* 6000* 7000*
Flow rate [m3/h] at 100 Pa
Exhaust duct: 1100 x 900 1100 x 900 1100 x 900 1100 x 900
Dimensions [mm]
*Option K2

Tab. 7 Ventilation

2.7 Pressure
Maximum working pressure: (see nameplate)

Pressure relief valve activating pressure at 50 Hz [bar]:

Maximum working pres‐ DSD 142 DSD 172 DSD 202 DSD 238
sure [bar]
8.5 — 10 10 10
9 11.5 — — —
12 — 14 14 14
15 — — 16 16

Tab. 8 Pressure relief valve activating pressure (50 Hz)

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 2 Technical Specification
2.8 Free air delivery

Pressure relief valve activating pressure at 60 Hz [bar]:

Maximum working pres‐ DSD 142 DSD 172 DSD 202 DSD 238
sure [bar]
7.5 — — — 10
8.5 — — 10 —
9 11.5 11.5 — —
12 14 14 14 14
15 — — — 16

Tab. 9 Pressure relief valve activating pressure (60Hz)

2.8 Free air delivery

FAD [m3/min] at 50 Hz mains frequency

Maximum working pres‐ DSD 142 DSD 172 DSD 202 DSD 238
sure [bar]
8.5 — 16 20.3 23.6
9 13.5 — — —
12 — 13 15.2 19.6
15 — — 12.4 14.4

Tab. 10 FAD (50 Hz)

FAD [m3/min] at 60 Hz mains frequency

Maximum working pres‐ DSD 142 DSD 172 DSD 202 DSD 238
sure [bar]
7.5 — — — 24.1
8.5 — — 19 —
9 12.3 16.1 — —
12 10.4 12.2 15.4 17.8
15 — — — 14.9

Tab. 11 FAD (60 Hz)

2.9 Cooling Oil Recommendation

A sticker showing the type of oil used is located near the oil separator tank filler.
Information on ordering cooling oil is found in chapter 11.

SIGMA FLUID
S–460 MOL FG–460/FG–680
Description Silicone-free Mineral oil Synthetic oil
synthetic oil

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6 DSD SIGMA CONTROL 9_6977 00 E
 2 Technical Specification
2.10 Cooling oil charge

SIGMA FLUID
S–460 MOL FG–460/FG–680
Application Standard oil for all applica‐ Standard oil for all ap‐ Specifically for applications
tions except in connection plications except in where the compressed air
with foodstuffs. connection with food‐ comes into contact with food‐
Particularly suitable for ma‐ stuffs. stuffs.
chines with a high duty cy‐ Particularly suitable for
cle. machines with a low
duty cycle.
Approval — — USDA H–1, NSF
Approved for the manufacture
of foodstuff packaging, meat
and poultry processing and
other food processing.
Viscosity at 45 mm2/s 44 mm2/s 50.7/70.0 mm2/s
40 °C (D 445; ASTM Test) (DIN 51562–1) (D 445; ASTM Test)
Viscosity at 7.2 mm2/s 6.8 mm2/s 8.2/710.4 mm2/s
100 °C (D 445; ASTM Test) (DIN 51562–1) (D 445; ASTM Test)
Flash point 238 °C 220 °C 245 °C
(D 92; ASTM Test) (ISO 2592) (D 92; ASTM Test)
Density at 864 kg/m3 — —
15 °C (ISO 12185)
Pour point −46 °C −33 °C —
(D 97; ASTM Test) (ISO 3016)
Demulsibility 40/40/0/10 min — —
at 54 °C (D 1401; ASTM Test)

Tab. 12 Cooling Oil Recommendation

2.10 Cooling oil charge

Option K1 Air-cooled

DSD 142 DSD 172 DSD 202 DSD 238

Total charge [l] 70 70 70 70
Topping up volume [l] 5 5 5 5

(minimum–maximum)

Tab. 13 Cooling oil charge (option K1)

Option K2 Water-cooled

DSD 142 DSD 172 DSD 202 DSD 238

Total charge [l] 54 54 54 54

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 2 Technical Specification
2.11 Motors and power

DSD 142 DSD 172 DSD 202 DSD 238

Topping up volume [l] 5 5 5 5

(minimum–maximum)

Tab. 14 Cooling oil charge (option K2)

Option W1/W2/W3 Heat recovery

The charge of cooling oil for machines with heat recovery is increased by the volume of oil in
the heat exchanger and connecting lines.

Option W1 DSD 142 DSD 172 DSD 202 DSD 238

Additional charge vol‐
ume [l]*
* Enter the volume required by your heat recovery system.

Tab. 15 Cooling oil charge (option W1)

Option W2 DSD 142 DSD 172 DSD 202 DSD 238

Additional charge vol‐ 6.6 7.8 11.3 14.8
ume [l]

Tab. 16 Cooling oil charge (option W2)

Option W3 DSD 142 DSD 172 DSD 202 DSD 238

Additional charge vol‐ 5.4 5.4 6.6 9.0
ume [l]

Tab. 17 Cooling oil charge (option W3)

2.11 Motors and power

2.11.1 Drive motor
DSD 142 DSD 172 DSD 202 DSD 238
Rated power [kW] 75 90 110 132
Enclosure protection IP 55 IP 55 IP 55 IP 55

Tab. 18 Drive motor

Rated speed at 50 Hz [rpm]

Maximum working pres‐ DSD 142 DSD 172 DSD 202 DSD 238
sure [bar]
8.5 — 1485 1485 1485
9 1485 — — —

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 2 Technical Specification
2.11 Motors and power

Maximum working pres‐ DSD 142 DSD 172 DSD 202 DSD 238
sure [bar]
12 — 1485 1485 1485
15 — — 1485 1485

Tab. 19 Drive motor rated speed (50 Hz)

Rated speed at 60 Hz [rpm]:

Maximum working pres‐ DSD 142 DSD 172 DSD 202 DSD 238
sure [bar]
7.5 — — — 1794
8.5 — — 1792 —
9 1188 1792 — —
12 1188 1188 1792 1794
15 — — — 1794

Tab. 20 Drive motor rated speed (60Hz)

2.11.2 Option K1
Fan motor
Rated power supply: 400V±10%/3/50Hz

DSD 142 DSD 172 DSD 202 DSD 238

Rated power [kW] 1.5 2.2 2.2 1.8/6.0
Rated speed [rpm] 960 970 970 970/1450
Enclosure protection IP 55 IP 55 IP 55 IP 55
Motor bearing re-greasing 2000 2000 2000 2000
interval [h]
Grease requirement, each
bearing [g]**
h = operating hours
** Transfer data from the motor nameplate to the table for reference purposes.

Tab. 21 Fan motor connection 400V/3/50Hz (option K1)

Rated power supply: 380V±10%/3/60Hz

DSD 142 DSD 172 DSD 202 DSD 238

Rated power [kW] 2.2 2.2 2.2 2.2
Rated speed [rpm] 1140 1140 1150 1150
Enclosure protection IP 55 IP 55 IP 55 IP 55
Motor bearing re-greasing 2000 2000 2000 2000
interval [h]
h = operating hours
* Transfer data from the motor nameplate to the table for reference purposes.

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 2 Technical Specification
2.11 Motors and power

DSD 142 DSD 172 DSD 202 DSD 238

Grease requirement, each
bearing [g]*
h = operating hours
* Transfer data from the motor nameplate to the table for reference purposes.

Tab. 22 Fan motor connection 380V/3/60Hz (option K1)

Rated power supply: 440V±10%/3/60Hz

DSD 142 DSD 172 DSD 202 DSD 238

Rated power [kW] 1.5 1.5 2.2 2.2
Rated speed [rpm] 1140 1140 1150 1150
Enclosure protection IP 55 IP 55 IP 55 IP 55
Motor bearing re-greasing 2000 2000 2000 2000
interval [h]
Grease requirement, each
bearing [g]*
h = operating hours
* Transfer data from the motor nameplate to the table for reference purposes.

Tab. 23 Fan motor connection 440V/3/60Hz (option K1)

Rated power supply: 460V±10%/3/60Hz

DSD 142 DSD 172 DSD 202 DSD 238

Rated power [kW] 1.5 1.5 2.2 2.2
Rated speed [rpm] 1140 1140 1150 1150
Enclosure protection IP 55 IP 55 IP 55 IP 55
Motor bearing re-greasing 2000 2000 2000 2000
interval [h]
Grease requirement, each
bearing [g]*
h = operating hours
* Transfer data from the motor nameplate to the table for reference purposes.

Tab. 24 Fan motor connection 460V/3/60Hz (option K1)

2.11.3 Option K2
Fan motor
DSD 142 DSD 172 DSD 202 DSD 238
Rated power [kW] 0.3 0.3 0.3 0.3
Rated speed [rpm] 1400 1400 1400 1400
1460* 1460* 1460* 1460*
* 60Hz

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10 DSD SIGMA CONTROL 9_6977 00 E
 2 Technical Specification
2.12 Sound pressure level

DSD 142 DSD 172 DSD 202 DSD 238

Enclosure protection IP 44 IP 44 IP 44 IP 44
* 60Hz

Tab. 25 Fan motor (option K2)

2.12 Sound pressure level

Operational state
■ Nominal volume flow
■ Nominal pressure

Measurement conditions
■ Free-field measurement to CAGI/PNEUROP PN8 NTC 2.3
■ Measurement distance: 1 m

Sound pressure lev‐ DSD 142 DSD 172 DSD 202 DSD 238
el [dB(A)]
At 50 Hz 68/66* 69/67* 70/68* 71(79**)/69*
At 60 Hz 70/66* 71/68* 73/69* 74/70*
* K2
** At higher speed

Tab. 26 Sound pressure level

2.13 Power Supply

Basic requirements

The machine is designed for a power supply conforming to EN 60204–1 (IEC 60204–1), section 4.3.
In the absence of other user-specified conditions, the limits laid down in this standard must be adhered
to.
It is recommended that the supplier and user confer and agree on the basis of the EN 60240–1, 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 from an earthed TN or TT three-phase supply.
Connection to an IT supply is not permitted without taking further measures (earth leak detection,
etc.).

Further requirements

Demands on a three-phase supply for a machine with the following equipment:

■ Variable frequency drive (SFC)
■ Refrigeration dryer powered from a transformer

This machine may only be supplied from an earthed TN or TT three-phase supply in which the neutral
point is earthed.

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 2 Technical Specification
2.14 Power supply specifications

The machine may not be connected to a three-phase supply in which one of the phases is earthed,
as this can lead to dangerous voltage surges.
Connection to an IT supply is not permitted without further measures being taken (earth leak detection,
specially designed frequency converter, etc.).

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

2.14 Power supply specifications

The following supply cable conductor cross sections (copper multicore) and fusing (slow-blow
class gL/gG) are selected according to German DIN VDE 0100–430 (IEC 60364–4–43 and
IEC 60364–4–473) and DIN VDE 0298-4 standards for 30 °C ambient temperature and wiring
type C.
➤ The conductor cross-sections should be changed accordingly if other conditions prevail.

Other conditions would include, for example:

■ higher temperature
■ other cable laying method
■ cable lengths >50 m

2.14.1 Mains frequency: 50 Hz

Rated power supply: 400V±10%/3/50Hz

DSD 142 DSD 172 DSD 202 DSD 238

Mains fusing [A] 200 200 250 315
Supply cable [mm ] 2 4x95 4x95 4x120 4x185
Current drawn [A] 155/153* 176/174* 219/210* 273/263*
* Option K2

Tab. 27 Connection details 400V/3/50Hz

2.14.2 Mains frequency: 60 Hz

Rated power supply: 380V±10%/3/60Hz

DSD 142 DSD 172 DSD 172 DSD 202 DSD 238
9 bar 12 bar
Mains fusing [A] 200 200 200 250 315
Supply cable [mm ] 2 4x95 4x95 4x95 4x120 4x185
Current drawn [A] 155/152* 185/182* 175/172* 230/225* 271/266*
* Option K2

Tab. 28 Connection details 380V/3/60Hz

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12 DSD SIGMA CONTROL 9_6977 00 E
 2 Technical Specification
2.15 Water-cooling

Rated power supply: 440V±10%/3/60Hz

DSD 142 DSD 172 DSD 172 DSD 202 DSD 238
9 bar 12 bar
Mains fusing [A] 160 200 200 250 315
Supply cable [mm2] 4x70 4x95 4x95 4x120 4x185
Current drawn [A] 138/135* 165/162* 156/153* 195/191* 234/230*
* Option K2

Tab. 29 Connection details 440V/3/60Hz

Rated power supply: 460V±10%/3/60Hz

DSD 142 DSD 172 DSD 172 DSD 202 DSD 238
9 bar 12 bar
Mains fusing [A] 160 200 160 250 250
Supply cable [mm ] 2 4x70 4x95 4x70 4x120 4x120
Current drawn [A] 132/129* 158/156* 150/147* 187/183* 225/220*
* Option K2

Tab. 30 Connection details 460V/3/60Hz

2.15 Option K2
Water-cooling
Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and location of the connection
ports.

2.15.1 Design data

Cooling water temperature rise 10 K

DSD 142 DSD 172 DSD 202 DSD 238

Max. permissible inlet 40 40 40 40
temperature [ C]
Water flow rate [m3/h] 7.1 8.4 10.4 12.7
Water pressure drop [bar] 1.7 1.7 1.7 1.7

Tab. 31 Cooling water temperature (ΔT=10K)

Cooling water temperature rise 30 K

DSD 142 DSD 172 DSD 202 DSD 238

Max. permissible inlet 20 20 20 20
temperature [ C]
Water flow rate [m3/h] 2.4 2.8 3.5 4.2

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 2 Technical Specification
2.15 Water-cooling

DSD 142 DSD 172 DSD 202 DSD 238

Water pressure drop [bar] 0.5 0.5 0.5 0.5

Tab. 32 Cooling water temperature (ΔT=30K)

Cooler specification

DSD 142 DSD 172 DSD 202 DSD 238

Material 1.4401 1.4401 1.4401 1.4401
Braze Copper (Cu) Copper (Cu) Copper (Cu) Copper (Cu)
Maximum working pres‐ 10 10 10 10
sure [bar]
(cooling water)
Max. permissible dis‐ 70 70 70 70
charge temperature [°C]
Unsuitable cooling medi‐ Seawater
um Consult KAESER on the suitability of water.

Tab. 33 Cooler specification (option K2)

2.15.2 Cooling water quality

Oil may contaminate the cooling water if a leak occurs.
➤ A special heat exchanger must be used for heating drinking water.
The specific heat capacity and required flow rate of the cooling water changes if antifreeze is
added.
➤ Consult KAESER Service to ensure optimum cooling-system performance.
It is imperative that measures for cooling water treatment and filtration are implemented.
KAESER can provide the names of companies specializing in cooling water analysis and the supply
of suitable treatment plant.

Characteristics/content Value
pH value 7,5–9
Hardness [dH] 4,0–8,5
Chloride (Cl) [mg/l] <150
Free chlorine gas (Cl2) [mg/l] <1
Sulphite (SO3) [mg/l] <1
Dissolved iron (Fe) [mg/l] <0,2
Hydrogen carbonat (HCO3) [mg/l] 70–300
Sulphate (SO4) [mg/l] <70
HCO3/SO4 >1
Electrical conductivity [µS/cm] 10–500
Ammonia (NH3) [mg/l] <2
Dissolved manganese (Mn) [mg/l] <0,1
Dissolved aluminium (Al) [mg/l] <0,2

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14 DSD SIGMA CONTROL 9_6977 00 E
 2 Technical Specification
2.16 Heat recovery

Characteristics/content Value
Dissolved nitrate (NO3) [mg/l] <100
Hydrogen sulphide (H2S) [mg/l] <0,05
Free aggressive carbon dioxide (CO2) [mg/l] <5
Glycol [%] <50
Solids (particle size) [mm] <0,1
Algae Not permitted

Tab. 34 Cooling water quality

2.16 Option W1/W2/W3

Heat recovery
2.16.1 Option W1
Prepared for external heat recovery
All connections are provided to accommodate an external heat exchanger.
The quality of the heat transfer medium and its required flow rate depend on the type of heat
exchanger used.

Maximum heat capacity DSD 142 DSD 172 DSD 202 DSD 238
available
[kW] 65.7 76.1 96.8 118.6
[MJ/h] 236 274 348 427
[kcal/h] 56475 65417 83233 101943

Tab. 35 Heat capacity (option W1)

2.16.2 Option W2/W3

Internal heat recovery
Generally water is used as the heat transfer medium. The water must meet the specification given
below in order not to damage the heat exchanger.
➤ Consult KAESER Service if you wish to use a different heat transfer medium.

Water quality specification

Characteristics/content Value
pH value 7,5–9
Hardness [°dH] 4,0–8,5
Chloride (Cl) [mg/l] <150
Free chlorine gas (Cl2) [mg/l] <1
Sulphite (SO3) [mg/l] <1

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 2 Technical Specification
2.16 Heat recovery

Characteristics/content Value
Dissolved iron (Fe) [mg/l] <0,2
Hydrogen carbonat (HCO3) [mg/l] 70–300
Sulphate (SO4) [mg/l] <70
HCO3/SO4 >1
Electrical conductivity [µS/cm] 10–500
Ammonia (NH3) [mg/l] <2
Dissolved manganese (Mn) [mg/l] <0,1
Dissolved aluminium (Al) [mg/l] <0,2
Dissolved nitrate (NO3) [mg/l] <100
Hydrogen sulphide (H2S) [mg/l] <0,05
Free aggressive carbon dioxide (CO2) [mg/l] <5
Glycol [%] <50
Solids (particle size) [mm] <0,1
Algae Not permitted

Tab. 36 Water quality specification

Heat exchanger specification

DSD 142 DSD 172 DSD 202 DSD 238

Material 1.4401 1.4401 1.4401 1.4401
Braze Copper (Cu) Copper (Cu) Copper (Cu) Copper (Cu)
Maximum working pres‐ 10 10 10 10
sure [bar]
(heat transfer medium)
Max. permissible dis‐ 100 100 100 100
charge temperature [°C]
Pressure drop [bar] <0,1 <0,1 <0,1 <0,1
Unsuitable heat transfer Seawater
media Consult KAESER about water types.

Tab. 37 Heat exchanger specification (option W2/W3)

Heat capacity

Maximum heat capacity DSD 142 DSD 172 DSD 202 DSD 238
available
[kW] 65.7 76.1 96.8 118.6
[MJ/h] 236 274 348 427
[kcal/h] 56475 65417 83233 101943

Tab. 38 Heat capacity (option W2/W3)

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16 DSD SIGMA CONTROL 9_6977 00 E
 2 Technical Specification
2.16 Heat recovery

Option W2 Flow rate for heating from 45 °C to 70 °C (equivalent to ΔT = 25K)

DSD 142 DSD 172 DSD 202 DSD 238

Flow rate [m3/h] 2.29 2.66 3.38 4.14

Tab. 39 Flow rate (option W2)

Option W3 Flow rate for heating from 15 °C to 70 °C (equivalent to ΔT = 55K)

DSD 142 DSD 172 DSD 202 DSD 238

Flow rate [m /h]
3 1.04 1.20 1.53 1.87

Tab. 40 Flow rate (option W3)

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9_6977 00 E DSD SIGMA CONTROL 17
 3 Safety and Responsibility
3.1 Basic Information

3 Safety and Responsibility

3.1 Basic Information
The machine is manufactured to the latest engineering standards and acknowledged safety regula‐
tions. Nevertheless, dangers can arise through its operation:
■ Danger to life and limb of the operator or third parties.
■ Impairments to the machine and other material assets.

DANGER
Disregard of these instructions can result in serious injury.
➤ Read the service manual carefully and take notice of the contents for safe machine operation.

➤ Use this machine only if it is in a technically perfect condition and only for the purpose for which
it is intended; observe all safety measures and the instructions in the service manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety.

3.2 Specified Use

The machine is intended solely for industrial use in generating compressed air. Any other use is
incorrect and does not comply with requirements. The manufacturer is not liable for any resulting
damages. The risk involved in such incorrect use is taken solely by the user.
➤ Keep to the specifications listed in this service manual.
➤ Operate the machine only within its performance limits and under the permitted ambient condi‐
tions.
➤ Do not use compressed air for breathing purposes unless it is specifically treated for such.
➤ Do not use compressed for any application that will bring it into direct contact with foodstuffs
unless it is specifically treated for this.

3.3 Improper Use

➤ Never direct compressed air at persons or animals.
➤ Cooling air, warmed after passing through the machine, may be used for heating purposes but
only when it poses no health risk to humans or animals. If necessary, hot cooling air should be
treated by suitable means.
➤ Do not allow the machine to take in toxic, acidic, flammable of explosive gases or vapours.
➤ Do not operate the machine in areas in which specific requirements with regard to explosion
protection are applied.

3.4 User's Responsibilities

3.4.1 Observe statutory and universally accepted regulations
This is, for example, nationally applied European directives and/or valid national legislation, safety
and accident prevention regulations.
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the machine.

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 3 Safety and Responsibility
3.4 User's Responsibilities

3.4.2 Qualified personnel

These are people who, by virtue of their training, knowledge and experience as well as their knowl‐
edge of relevant regulations can assess the work to be done and recognise the possible dangers
involved.

Authorised operators possess the following qualifications:

■ are of legal age,
■ are conversant with and adhere to the safety instructions and sections of the service manual
relevant to operation,
■ have received adequate training and authorisation to operate electrical and compressed air de‐
vices.
■ Additional qualifications for compressors with refrigeration dryers:
─ Adequate training and authorisation ton refrigeration devices.

Authorised installation and maintenance personnel have the following qualifications:

■ are of legal age,
■ have read, are conversant with and adhere to the safety instructions and sections of the service
manual applicable to installation and maintenance,
■ are fully conversant with the safety concepts and regulations of electrical and compressed air
engineering,
■ are able to recognise the possible dangers of electrical and compressed air devices and take
appropriate measures to safeguard persons and property,
■ have received adequate training and authorisation for the safe installation and maintenance on
this equipment.
■ Additional qualifications for compressors with refrigeration dryers:
─ fully conversant with the safety concepts and regulations concerning refrigeration devices,
─ must be able to recognise the possible dangers of refrigeration devices and take appropriate
measures to safeguard persons and property.

➤ Ensure that operating, installation and maintenance personnel are qualified and authorised to
carry out their tasks.

3.4.3 Adherence to inspection schedules and accident prevention regulations

The machine is subject to local inspection schedules.

Examples of German inspection schedules

➤ Recurring inspections according to BGR 500, chapter 2.11:

The user must ensure that the machine's safety devices are checked for function as required or
at least annually.
➤ Oil changing according to BGR 500, chapter 2.11:
The user must ensure that the cooling oil is changed as required or at least annually and the oil
change must be documented. This requirement may be waived if an oil analysis proves that the
oil is still usable.

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 3 Safety and Responsibility
3.5 Dangers

➤ Keep to inspection intervals in accordance with the Ordinance on Industrial Safety and Health
with maximum intervals as laid down in §15.

Inspection Inspection interval Inspecting authority

Installation and equipment Before commissioning Approved supervisory body
inspection
Internal inspection Every 5 years after installation or the last Approved supervisory body
inspection
Strength test Every 10 years after installation or the last Approved supervisory body
inspection

Tab. 41 Inspection intervals according to Ordinance on Industrial Safety and

Health

3.5 Dangers
Basic Information

Information concerning the various forms of danger that can arise during machine operation are found
here.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.

3.5.1 Safely Dealing with Sources of Danger

Information concerning the various forms of danger that can arise during machine operation are found
here.

Electricity

➤ Allow only qualified and authorised electricians or trained personnel under the supervision of a
qualified and authorised electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations .
➤ Before every start-up, the user must make sure there is adequate protection against electric shock
from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Switch off any external power sources.
These could be connections to floating contacts or electrical machine heating, for example.
➤ Use fuses corresponding to machine power.
➤ Check regularly that all electrical connections are tight and in order.

Forces of compression

Compressed air is contained energy. Uncontrolled release of this energy can cause serious injury or
death. The following information concernes work on components that could be under pressure.
➤ Close shut-off valves or otherwise isolate the machine from the air main to ensure that no com‐
pressed air can flow back into the machine.

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3.5 Dangers

➤ Vent all pressurized components and chambers completely.

➤ Do not carry out welding, heat treatment or mechanical modifications to pressurized components
(e.g. pipes and vessels) as this influences the component's resistance to pressure.
The safety of the machine is then no longer ensured.

Compressed air quality

➤ Never directly inhale compressed air.

➤ Use appropriate systems for air treatment before using the compressed air from this machine as
breathing air and/or for the processing of foodstuffs.
➤ Use foodstuff-compatible cooling oil whenever compressed air is to come into contact with food‐
stuffs.

Spring tension

Springs under tension or compression represent contained energy. Uncontrolled release of this en‐
ergy can cause serious injury or death.
Minimum pressure/check valves, pressure relief valves and inlet valves are powerfully spring-loaded.
➤ Do not open or dismantle any valves.

Rotating components

Touching the fan wheel, the coupling or the belt drive while the machine is switched on can result in
serious injury.
➤ Do not open the enclosure while the machine is switched on.
➤ Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Wear close-fitting clothes and a hair net if necessary.
➤ Make sure all covers and safety guards are in place and secured before starting.

Temperature

➤ Avoid contact with hot components.

These include, for example, compressor airends or blocks, oil and compressed air lines, coolers,
oil separator tanks, motors and machine heaters.
➤ Wear protective clothing.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.

Noise

➤ Operate the machine only with full soundproofing.

➤ Wear hearing protection if necessary.
The pressure relief valve blowing off can be particularly loud.

Operating materials

➤ Strictly forbid fire, open flame and smoking.

➤ Follow safety regulations when dealing with lubricants and chemical substances.
➤ Avoid contact with skin and eyes.
➤ Do not inhale oil mist or vapour.

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3.5 Dangers

➤ Do not eat or drink while handling cooling and lubricating fluids.

➤ Keep suitable fire extinguishing agents ready for use.
➤ Use only KAESER approved operating materials.

Unsuitable spare parts

➤ Use only spare parts approved by the manufacturer for use in this machine.
Unsuitable spare parts compromise the safety of the device.
➤ Use only genuine KAESER pressure components.

Conversion or modification of the machine

➤ Do not permit conversion or modification of the machine as this can compromise function and
safe working.

Extension or modification of the compressed air system

➤ Extension or modification of the compressor station:

Check the blow-off capacity of pressure relief valves on air receivers and compressed air lines
before installing any new machines.
➤ If the blow-off capacits is insufficient:
Install pressure relief valves with larger blow-off capacity.

3.5.2 Safe Machine Operation

Information on safe conduct when handling the machine is found here.

Transport

➤ Use suitable lifting gear that conforms to local safety regulations.

➤ Allow transport only by personnel trained in the safe movement of goods.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the centre of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.

Installation

➤ Install the machine in a suitable compressor room.

➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements with regard to explosion protection are in
force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure adequate ventilation.

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 3 Safety and Responsibility
3.6 Safety Devices

➤ Ensure that required ambient conditions are maintained with regard to:
■ ambient temperature and humidity,
■ clean inlet air with no damaging contaminants,
■ inlet air free of explosive or chemically unstable gases or vapours,
■ inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen
sulphide.
➤ Do not position the machine in warm exhaust air from other machines.
➤ Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.

Decommissioning, storage, disposal

➤ Drain out fluids and dispose of according to environmental regulations.

These include, for example, compressor oil and cooling water.
➤ Give refrigerant only to authorised bodies for disposal.
➤ Dispose of the machine in accordance with local environmental regulations.

3.5.3 Organisational Measures

➤ Designate personnel and their responsibilities.
➤ Give clear instructions on reporting faults and damage to the machine.
➤ Give instructions on fire reporting and fire-fighting measures.

3.5.4 Danger Areas

The table gives information on the areas dangerous to personnel.
Only authorised personnel may enter these areas.

Activity Danger area Authorised personnel

Transport Within a 3 m radius of the machine. Installation personnel for transport
preparation.
No personnel during transport.
Beneath the lifted machine. No personnel!
Installation Within the machine. Installation personnel
Within 1 m radius of the machine and its supply
cables.
Operation Within a 1 m radius of the machine. Operating personnel
Maintenance Within the machine. Maintenance personnel
Within a 1 m radius of the machine.

Tab. 42 Danger Areas

3.6 Safety Devices

Various safety devices ensure safe working with the machine.
➤ Do not change, bypass or disable safety devices.
➤ Check safety devices for correct function regularly.

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 3 Safety and Responsibility
3.7 Safety signs

➤ Do not remove or obliterate labels and notices.

➤ Ensure that labels and notices are clearly legible.

Further information More information on safety devices is contained in chapter4, section 4.6.

3.7 Safety signs

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

Fig. 2 Location of safety signs

Item Sign Meaning

1 Danger of fatal injury from electric shock!
➤ Before beginning any work on electrical equipment:
Switch off the mains disconnecting device, lock it in the off position and check that
the machine is free of voltage.
2 Hot surface!
Risk of burns caused by contact with hot components
➤ Do not touch the surface.
➤ Wear long-sleeved garments (not synthetics such as polyester) and protective
gloves.
3 Risk of serious lacerations or even severing of extremities (fingers) from rotating com‐
ponents.
➤ Operate the machine only with closed safety guards, access doors and panels.
➤ Switch off and lock out the power supply disconnecting device and check that no
voltage is present before opening any machine enclosure or guard.
4 Risk of injury caused by an automatic machine start!
➤ Switch off and lock out the power supply disconnecting device and check that no
voltage is present before opening any machine enclosure or guard.

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 3 Safety and Responsibility
3.8 In emergency

Item Sign Meaning

5 Risk of fatal injury caused by dismantling valves (spring-loaded or under pressure)
➤ Do not open or dismantle valves.
➤ Call an authorized Service Technician if a fault occurs.
6 Serious injury, particularly to the eyes, can result from foreign objects being thrown
out from rotating components.
➤ Do not allow anything to fall through the ventilation grille
➤ Do not work above the machine if it is switched on.
7 Incorrect oil levels can cause damage to the machine or excessive oil content in the
compressed air.
➤ Check the oil level regularly and correct as necessary.

Tab. 43 Safety signs

3.8 In emergency
3.8.1 Correct fire fighting
Suitable extinguishing agents
■ Foam
■ Carbon dioxide
■ Sand or earth

Unsuitable or unsafe extinguishing agents

■ Strong jet of water

1. Keep calm.
2. Give the alarm.
3. Shut off supply lines if possible.
For example:
■ Power supply disconnecting device (all phases)
Option K2 ■ Cooling water
Option W1–W3 ■ Heat recovery system
4. Move to safety.
For example:
■ Warn persons in danger
■ Help incapacitated persons
■ Close the doors
5. Try to extinguish the fire if you have the skill to do so.

3.8.2 Remove any cooling oil from your person

➤ Eye contact:
Rinse eyes thoroughly with lukewarm water and seek medical assistance.
➤ Skin contact:
Wash off immediately.

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 3 Safety and Responsibility
3.9 Warranty

3.9 Warranty
This service manual contains no independent warranty commitment. Our general terms and condi‐
tions of business apply with regard to warranty.
A condition of our warranty is that the machine is used for the purpose for which it is intended under
the conditions specified.
Due to the multitude applications for which the machine is suitable the obligation lies with the user to
determine its suitability for his specific application.

In addition, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ unauthorised modifications,
■ incorrect maintenance,
■ incorrect repair.

Correct maintenance and repair includes the use of original spare parts and operating materials.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.

3.10 Environmental Protection

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

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 4 Design and Function
4.1 Enclosure

4 Design and Function

4.1 Enclosure

Fig. 3 Enclosure
1 Control cabinet door
2 Latch
3 Access door

The enclosure, when closed, serves various functions:

■ sound insulation,
■ protection against contact with components,
■ cooling air flow control.

Safe and reliable operation is only assured with the enclosure closed.
Access doors are hinged to swing open and removable panels can be lifted off.
Latches are released by a key supplied with the machine.

4.2 Functional Description of the Machine

Functional description using an air-cooled machine as an example.

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 4 Design and Function
4.3 Floating relay contacts

Fig. 4 Machine layout

1 Inlet valve 6 Control cabinet
2 Minimum pressure/check valve 7 Oil separator tank
3 Drive motor 8 Air filter
4 Oil filter 9 Oil/air cooler
5 Airend

Ambient air is cleaned as it is drawn in through the filter 8 .

The air is then compressed in the airend 5 .
The airend is driven by an electric motor 3 .
Cooling oil is injected into the airend. It lubricates moving parts and forms a seal between the rotors
themselves and between them and the airend casing. This direct cooling in the compression chamber
ensures a very low airend discharge temperature.
Cooling oil recovered from the compressed air in the oil separator tank 7 gives up its heat in the oil
cooler 9 . The oil then flows through the oil filter 4 and back to the point of injection. Pressure within
the machine keeps the oil circulating. A separate pump is not necessary. A thermostatic valve main‐
tains optimum cooling oil temperature.
Compressed air, freed of cooling oil in the oil separator tank 7 , flows through the minimum pressure/
check valve 2 into the air cooler 9 . The minimum pressure/check valve ensures that there is always
a minimum internal air pressure sufficient to maintain cooling oil circulation in the machine.
The air cooler brings down the compressed air temperature of only 5 to 10 K above ambient. Most of
the moisture carried in the air is removed during this cooling process.

4.3 Floating relay contacts

Floating relay contacts are provided for the transfer of signals, messages.
Information on location, loading capacity and type of message or signal is found in the electrical
diagram.
If the floating relay contacts are connected to an external voltage source, voltage may be
present even when the machine is isolated from the power supply.

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 4 Design and Function
4.4 Options

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

4.4.1 Option K2
Water-cooling
Plate heat exchangers in stainless steel are used for water-cooled machines.

Fig. 5 Water-cooling (option K2)

1 Oil cooler 3 Cooling water connection
2 Compressed air cooler 4 Cooling water connection

4.4.2 Option W1/W2/W3

Heat recovery
Option W1 Prepared for external heat recovery

Connections are provided for an external system to recover surplus heat. A thermostatic valve in the
machine keeps the cooling oil at the ideal working temperature.
The external heat recovery system takes heat from the cooling oil via a heat transfer medium. The
available heat to be recovered depends on the operating conditions of the machine.

Option W2/W3 Internal heat recovery

A plate-type heat exchanger is installed for internal heat recovery. A thermostatic valve in the machine
keeps the cooling oil at the ideal working temperature.
The plate-type heat exchanger transfers heat from the cooling oil to a heat transfer medium. The
available heat to be recovered depends on the operating conditions of the machine.

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 4 Design and Function
4.5 Operating modes and control modes

Fig. 6 Internal heat recovery (option W2/W3)

1 Plate-type heat exchanger

4.4.3 Option H1
Machine mountings
These mountings allow the machine to be anchored firmly to the floor.

Fig. 7 Machine mountings

4.5 Operating modes and control modes

4.5.1 Operating modes
The machine operates in the following modes:
■ LOAD:
The inlet valve is open. The block delivers compressed air to the air system.
The drive motor runs under full load.
■ IIDLE:
The inlet valve is closed. The minimum pressure / check valve shuts off the oil separator from
the air system. The oil separator tank is vented.
A small volume of air circulates through the bleed hole in the inlet valve, through the airend and
back to the inlet valve via the venting valve.
The compressor motor runs without load and draws little current.
■ STANDSTILL:
The inlet valve is closed. The minimum pressure / check valve shuts off the oil separator from
the air system. The oil separator tank is vented.
The drive motor is stopped.
Option C1 ■ PROPORTIONAL:
With the help of a control valve (proportional controller), the degree of opening of the inlet valve
is continuously varied in relation to the actual air demand. The airend delivers compressed air to
the air system.
The load and power consumption of the drive motor rises and falls with the air demand.
The regulating valve is factory set. The setting should not be changed without consultation with
KAESER Service.

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 4 Design and Function
4.5 Operating modes and control modes

4.5.2 Control modes

Using the selected control mode, the controller switches the drive motor according to definite rules
(the control mode) between the various operating modes in order to compensate for air being drawn
off by consumers and maintain the machine's working pressure between the preset cut-in and cut-
out pressures.

SIGMA CONTROL can work in the following control modes:

■ DUAL
■ QUADRO
■ VARIO
■ DYNAMIC
Option C1 ■ MODULATING control

DUAL

In the DUAL control mode, the machine is switched back and forth between LOAD and IDLE to
maintain pressure between the preset minimum and maximum values. When maximum pressure is
reached, the machine switches to IDLE. When the preset idle period has elapsed, the machine
switches to STANDSTILL.
The shorter the idle period setting, the sooner (and more frequently) the motor is stopped.

QUADRO

In the QUADRO mode, the controller operates as in the DUAL mode during periods of high air demand
by switching between LOAD and IDLE, but during periods of low air demand it switches directly to
STANDSTILL.
This mode of control requires two preset time periods: the running period and the idle/standstill pe‐
riod.
The shorter these periods, the sooner (and more frequently) the motor stops.

VARIO

The VARIO mode is based on the DUAL control mode. The difference to DUAL is that the idle period
is automatically lengthened or shortened to compensate for higher or lower drive motor starting fre‐
quencies.

DYNAMIC

The DYNAMIC mode is based on the DUAL control mode. As opposed to DUAL, this control mode
switches the drive motor directly to STANDSTILL at low temperature. At higher motor temperatures,
it switches to IDLE until the motor has cooled down enough.
The lower the drive motor temperature, the sooner (and, therefore, more often and longer) it is stop‐
ped.

Option C1 MODULATING control

MODULATING control is based on the DUAL control mode. The difference to DUAL is that the air
delivery is continuously varied within the control range of the machine.
This control mode is not available on variable speed machines with a frequency-controlled
drive (SFC).

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 4 Design and Function
4.6 Safety devices

Compressed air demand Operating modes

rises MODULATING
LOAD
falls MODULATING
IDLE
STANDSTILL

Tab. 44 Operating modes under MODULATING control

4.6 Safety devices

The following safety devices are provided and may not be modified in any way.
■ EMERGENCY STOP button
For immediate shutdown of the machine. The motor remains stopped. The pressure system is
vented.
■ Pressure relief valve
This valve protects the system from excessive pressure. It is preset at the factory.
■ Enclosures and covers over moving parts and electrical connections
These protect against accidental contact.

4.7 SIGMA CONTROL Keys and Indicators

Fig. 8 Keys

Item Description Function

1 «ON» Switches on the machine.
The programmed operating mode is active.
2 «OFF» Switches the machine off.
3 «Clock» Switches clock control on and off.
4 «Remote control» Switches remote control on and off.
5 «LOAD/IDLE» Toggles the compressor between LOAD and IDLE operating modes.

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 4 Design and Function
4.7 SIGMA CONTROL Keys and Indicators

Item Description Function

6 «DOWN» Scrolls down the menu options.
Reduces a parameter value.
7 «UP» Scrolls up the menu options.
Increases a parameter value.
8 «escape» Returns to the next higher menu option level.
Exits the edit mode without saving.
Returns to the main menu when held down at least 10 seconds.
9 «enter» Only affects the value in the third line of the display.
Enters the selected menu option.
Exits the edit mode and saves.
10 «Events and Displays the event memory.
information» Selection is possible from every menu.
Return with «esc» key.
11 «Reset» Signifies recognition of alarms and warning messages.
Resets the event memory (when permitted).

Tab. 45 Keys

Fig. 9 Indicators

Item Description Function

12 Display field Alphanumeric display with 4 lines.
13 Alarm Flashes red when an alarm occurs.
Lights continuously when acknowledged.
14 Communication Lights red if communication via the Profibus interface is interrupted.
15 Warning Flashes yellow for:
■ maintenance work due,
■ warning messages

Lights continuously when acknowledged.

16 Controller power Lights green when the power supply to the controller is switched on.

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 4 Design and Function
4.7 SIGMA CONTROL Keys and Indicators

Item Description Function

17 LOAD Lights green when the compressor is running under LOAD.
18 IDLE Lights green when the compressor is running in IDLE.
Flashes when the «LOAD/IDLE» toggle key is pressed.
19 Machine ON Lights green when the machine switched on.
20 Clock The LED lights when the machine is in clock control.
21 Remote control The LED lights when the machine is in remote control.

Tab. 46 Indicators

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 5 Installation and Operating Conditions
5.1 Safety

5 Installation and Operating Conditions

5.1 Safety
➤ Strictly forbid fire, open flame and smoking.
➤ If welding is carried out on or near the machine, take adequate measures to prevent sparks or
heat from igniting oil vapours or parts of the machine.
➤ The machine is not explosion-proof:
Do not operate in areas in which specific requirements with regard to explosion protection are in
force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure that required ambient conditions are maintained with regard to:
■ ambient temperature and humidity,
■ clean inlet air with no damaging contaminants,
■ inlet air free of explosive or chemically unstable gases or vapours,
■ inlet air free of acid/alkaline forming substances, particularly ammonia, chlorine or hydrogen
sulphide.
➤ Keep suitable fire extinguishing agents ready for use.

5.2 Installation Conditions

5.2.1 Place of installation and distances
The machine is intended for installation in an appropriate machine room. Information on distances
from walls and ventilation is given below.
The distances quoted are recommended distances and ensure unhindered access to all ma‐
chine parts.
➤ Please consult KAESER if they cannot be kept to.

Precondition The floor must be level, firm and capable of bearing the weight of the machine.

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 5 Installation and Operating Conditions
5.2 Installation Conditions

Fig. 10 Recommended installation and dimensions [mm]

A Exhaust fan
B Exhaust air duct
Z Cooling air inlet aperture

CAUTION
Ambient temperature too low!
Frozen condensate and highly viscous cooling oil can cause damage when starting the machine.
➤ Make sure that the temperature of the machine is at least +3 °C before starting.
➤ Heat the machine room adequately or install an auxiliary heater.

1. If installed outdoors, protect the machine against frost, direct sunlight, dust and rain.
2. Ensure accessibility so that all work on the machine can be carried out without danger or hin‐
drance.

5.2.2 Ensure adequate ventilation.

If the ventilation is insufficient, a dangerous vacuum can build up in the machine room.

➤ Ensure that the volume of air flowing into the machine room is at least equivalent to that being
removed from it by the machine and exhaust fan.
➤ Make sure that the machine and exhaust fan can only operate when the inlet aperture is actually
open.
➤ Keep the inlet and exhaust apertures free of obstructions so that the cooling air can flow freely
through the machine room.

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 5 Installation and Operating Conditions
5.3 Operating the Machine in an Air System.

5.2.3 Exhaust duct design

The machine can only overcome the air resistance at the cooling air inlet and exhaust determined by
the duct design. Any additional air resistance will reduce airflow and deteriorate machine cooling.
➤ Consult the KAESER service representative before deciding on:
■ the design of the exhaust air ducting
■ the intersection between the machine and the exhaust air duct
■ the length of the ducting
■ the number of duct bends
■ the design of flaps or shutters
Use only motorised ventilation flaps and louvers on variable frequency drive (SFC) machines.
Flaps or louvers that open through the pressure of the airflow against the force of gravity do not
open sufficiently at low cooling fan speeds.

Further information Further information on installation of exhaust air ducts can be found in chapter 13.3.

5.3 Operating the Machine in an Air System.

If the machine is supplying an air system, the system operating pressure may not exceed 16 bar.
When charging a fully vented air system there is generally a very high rate of airflow through the air
treatment devices. These cannot function correctly under such conditions. Air quality suffers.
To ensure the desired air quality when charging a vented air network, we recommend the installation
of an air main charging system.
➤ Consult KAESER for advice on this subject.

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 6 Installation
6.1 Safety

6 Installation
6.1 Safety
Follow the instructions below for safe installation.
Warning instructions are always given before a potentially dangerous action.

Basic safety instructions

1. Follow the instructions in chapter 3 'Safety and Responsibility'.

2. Installation work may only be carried out by authorized personnel.
3. Before switching on, make sure that:
■ no one is working on the machine,
■ all access doors and panels are closed and secure.

Working on live components.

1. Work on electrical equipment may only be carried out by authorized electricians.

2. Switch off and lock out the supply disconnecting (isolating) device and check that no voltage is
present.
3. Check that there is no voltage on floating relay contacts.

Working on pressure systems

1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 bar.
4. Do not open or dismantle any valves.

Working on the drive system

1. Switch off and lock out the supply disconnecting (isolating) device and check that no voltage is
present.
2. Do not open the cabinet while the machine is switched on.

Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.

6.2 Reporting Transport Damage

1. Check the machine for visible and hidden transport damage.
2. Inform the carrier and the manufacturer in writing of any damage without delay.

6.3 Making the Compressed Air Connection

Precondition The compressed air system is vented completely.

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 6 Installation
6.4 Connecting the Power Supply

Fig. 11 Compressed air connection

1 Axial compensator or hose
2 Shut-off valve

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

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

6.4 Connecting the Power Supply

Precondition The supply disconnecting device is switched off
The device is locked off
A check has been made that no voltage is present.

1. Have the power supply connected only by authorized installation personnel or an authorized
electrician.
2. Carry out safety measures as stipulated in relevant regulations (IEC 364, for example or
DIN VDE 0100) and in national accident prevention regulations (BGV A3 in Germany). In addition,
observe the regulations of the local electricity supplier.
3. Check the permissible reaction time of overload protection devices.
4. Select supply cable conductor cross-sections and fusing in accordance with local regulations.
5. The user must provide the machine with a lockable power supply disconnecting device.
This could be, for example, a mains power switch with fused supply. If a circuit breaker is used
it must be suitable for the motor starting characteristics.
6. Check that the tappings on the control voltage transformer are connected according to the supply
voltage.
If not, change the tappings to suit the power supply voltage.

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

7. Connect the machine to the power supply.

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

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 6 Installation
6.5 Options

6.5 Options
6.5.1 Option H1
Ânchoring the machine
➤ Use appropriate fixing bolts to anchor the machine.

Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.3.

6.5.2 Option K2
Connecting the Cooling Water
➤ Take the electrochemical series into consideration and choose suitable materials for water
connections.
➤ Keep the effect of pressure surge on the cooler as low as possible.
➤ Install an expansion tank to act as a damper if pressure surges cannot be avoided.

Fig. 12 Connecting the cooling water

A Cooling water outlet 12 Connection port with stopper
B Cooling water inlet 17 Pressure relief valve
10 Shut-off valve

1. The user is to provide the following fittings:

■ dirt trap with max. 0.1 mm strainer mesh,
■ shut-off valves 10 and connection ports 12 for maintenance and venting,
■ pressure relief valve 17 to prevent build-up of excessive pressure.
Blowoff pressure and capacity are related to the user's installation design. The technical
specification of the cooler must be taken into consideration.
2. Connect the cooling water line to the fitting.
3. Open the shut-off valve on the cooling water outlet A .
4. Slowly open the cooling water inlet shut-off valve B to gradually fill the cooler with water.
5. Vent the water lines.

Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connection
ports.

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 6 Installation
6.5 Options

6.5.3 Option W1/W2/W3

Connecting the Heat Recovery System
➤ Take the electrochemical series into consideration and choose suitable materials for con‐
nections.
➤ Keep the effect of pressure surge on the heat exchanger as low as possible.
➤ Install an expansion tank to act as a damper if pressure surges cannot be avoided.
➤ Install appropriate regulating devices if the heat transfer medium is to be kept constant.

WARNING
Cooling oil in the heat transfer medium.
Oil may contaminate the medium if a leak occurs.
➤ Do not use the transfer medium as drinking water.

6.5.3.1 Option W1
Connecting the external heat recovery system

An unsuitable heat exchanger or incorrect installation may influence the cooling oil circuit within
the compressor. Damage to the machine will follow.
➤ Consult KAESER on a suitable heat exchanger and expert installation.
➤ Carry out installation and connection of the heat exchanger in accordance with specifications
from KAESER and the exchanger manufacturer.

6.5.3.2 Option W2/W3

Connecting the internal heat recovery system

Fig. 13 Connecting the heat recovery system

A Outlet 12 Connection port with stopper
B Inlet 17 Pressure relief valve
10 Shut-off valve

1. The user is to provide the following fittings:

■ dirt trap with max. 0.1 mm strainer mesh,
■ shut-off valves 10 and connection ports 12 for maintenance and venting,
■ pressure relief valve 17 to prevent build-up of excessive pressure.
Blowoff pressure and capacity are related to the user's installation design. The technical
specification of the heat exchanger must be taken into consideration.
2. Connect the supply lines and fittings
3. Open the shut-off valve 10 at the inlet A .

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 6 Installation
6.5 Options

4. Slowly open the shut-off valve 10 at the inlet B to gradually fill the heat exchanger with the heat
transfer medium.
5. Bleed the lines.

Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connection
ports.

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 7 Initial Start-up
7.1 Safety

7 Initial Start-up
7.1 Safety
Instructions for Safe Initial Start-up of the Machine.
Warning instructions are always given before a potentially dangerous action.

Basic safety instructions

1. Follow the instructions in chapter 3 'Safety and Responsibility'.

2. Have installation work carried out by authorized installation personnel only.
3. Before switching on, make sure that:
■ no one is working on the machine,
■ all access doors and panels are closed and secure.

Working on live components

1. Have work on electrical equipment carried out by authorized electricians only.

2. Switch off and lock out the power supply disconnecting (isolating) device and check that no volt‐
age is present.
3. Check that there is no voltage on floating relay contacts.

Working on pressure systems

1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 bar.
4. Do not open or dismantle any valves.

Working on the drive system

1. Switch off and lock out the power supply disconnecting (isolating) device and check that no volt‐
age is present.
2. Do not open the cabinet while the machine is switched on.

Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.

7.2 Instructions to be Observed before before Every Start-Up

Incorrect or improper start-up can cause injury to persons and damage to the machine.

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 7 Initial Start-up
7.3 Checking positioning and operating conditions

➤ Start-up may only be carried out by authorized installation and service personnel who have been
trained on this machine.

Special measures for initial start-up after storage

Storage period lon‐ Measure

ger than
12 months ➤ Change the oil filter.
➤ Change the oil separator cartridge.
➤ Change the cooling oil.
➤ Have the motor bearings checked by an authorized KAESER service rep‐
resentative.
36 months ➤ Have the overall technical condition checked by an authorized KAESER
Service representative.

Tab. 47 Initial start-up after storage

7.3 Checking positioning and operating conditions

➤ Check and confirm all the items in the checklist before initially starting the machine.

To be checked See Confirmed?

chapter
➤ Are the operators fully conversant with safety regulations? –
➤ Have all the positioning conditions been fulfilled? 5
➤ Is a user's lockable power supply disconnecting device installed? 6.4
➤ Does the power supply conform to the specifications on the name‐ 2.1
plate?
➤ Are the power supply cable conductor cross-sections and fuse ratings 2.14
adequate?
➤ Have all electrical connections been checked for tightness? –
➤ The check must be repeated after 50 operating hours.
➤ Is a shut-off valve fitted to compressed air outlet? 6.3
➤ Has the connection to the air system been made with a hose or axial 6.3
compensator?
➤ Sufficient cooling oil in the separator tank? 10.13
(oil level indicator outside the red zone)
➤ Drive motor overload protection switch set according to the mains volt‐ 7.4
age?
➤ Fan motor overload protection switch set according to the mains volt‐ 7.5
age?
➤ Is there sufficient cooling oil in the airend? 7.6
➤ Is the machine firmly anchored to the floor? 6.5.1
(option H1)
➤ Supply of cooling water ensured? 6.5.2
(option K2)

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 7 Initial Start-up
7.4 Setting the overload protection cut-out

To be checked See Confirmed?

chapter
➤ Are all access doors closed and latched and all removable panels in –
place and secured?

Tab. 48 Positioning and operating conditions checklist

7.4 Setting the overload protection cut-out

In the star-delta configuration, the phase current is fed to the drive motor via the overload protection
cut-out. This phase current is 0.58 times the rated motor current (see nameplate in the control cabi‐
net).
To prevent voltage fluctuations, temperature influences or component tolerances operating the
overload protection cut-out, the setting can be higher than the arithmetical phase current.

➤ Check the overload protection cut-out setting.

The overload protection cut-out shuts the machine down despite being correctly set?
➤ Contact KAESER Service.

7.5 Setting the motor overload protection switch

In direct on-line starting, the current for the fan motor is fed via the motor overload protection switch.
To prevent the overload protection switch from being triggered by voltage fluctuations, temper‐
ature influences or component tolerances, the setting can be higher than the motor rated current
(see motor nameplate).
➤ Check the motor overload protection switch setting.
The overload switch shuts the machine down despite being correctly set?
➤ Contact KAESER Service.

7.6 Pouring cooling oil into the airend

Before starting the compressor for the very first time and before re-starting after a shutdown period
of more than 3 months it is necessary to pour a quantity of cooling oil into the airend.
A label showing the type of oil used is found near the oil separator tank filling port.
➤ Use the same type of oil.

Material 4 lCooling oil

Precondition The supply disconnecting device is switched off,

the device is locked off,
a check has been made that no voltage is present.

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 7 Initial Start-up
7.7 Check Direction of Rotation

Fig. 14 Inlet valve filling port

1 Screw plug
2 Inlet valve

1. Unscrew the filler plug from the inlet valve.

2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug.

Fig. 15 Coupling
1 Airend 3 Safety screen
2 Coupling 4 Arrow showing direction of rotation

1. Remove the safety screen 3 .

2. Turn the airend 1 by turning the coupling 2 by hand in the direction indicated by the arrow 4 .
3. Replace the safety screen 3 .

7.7 Check Direction of Rotation

The machine is designed for a clockwise phase sequence.
Ideally, the direction of phase rotation should be measured with a phase sequence meter.
Alternatively, start the machine very briefly and observe the direction of rotation of the motor cooling
fan.
1. Check the direction of phase rotation with a phase sequence meter.
2. If the direction is incorrect, reverse the supply phases L1 and L2.

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 7 Initial Start-up
7.8 Starting the Machine for the First Time

You have no phase sequence meter?

➤ Switch the machine on and off again the moment the drive motor begins to turn.
➤ Compare the direction of rotation of the motor with the arrows on the motor and the airend
casing.
➤ If the direction is incorrect, reverse supply phases L1 and L2.

7.8 Starting the Machine for the First Time

Precondition No personnel are working on the machine,
all access doors are closed,
all removable panels in place and secured.

1. Open the shut-off valve to the air system.

2. Switch on the power supply disconnecting device.
After the controller has carried out a self-test, the green Power ON LED lights continuously.
3. If required:
Change the display language as described in chapter 7.10.
4. Press the «LOAD/IDLE» key.
The green IDLE LED lights continuously.
5. Press the «ON» key.
The green Machine ON LED lights continuously and the machine runs up in IDLE. This ensures
that cooling oil is gently distributed throughout the machine.
6. After at least 1 minute in IDLE:
Press the «LOAD/IDLE» key.
The machine switches to LOAD and delivers compressed air.
➤ Keep an eye on the machine during the first few hours of operation to ensure that it is
operating correctly.
➤ After the first 50 operating hours, check all electrical connections and tighten where nec‐
essary.

7.9 Setting the Setpoint Pressure

The setpoint pressure p1 is factory set to the highest possible value.
Adjustment is necessary for individual operating conditions.
Do not set the setpoint pressure of the machine higher than the maximum working pressure of
the air system.
The machine may not toggle more than twice per minute between LOAD and IDLE.
To reduce the cycling (toggling) frequency:
➤ Increase the difference between cut-in and cut-out pressure.
➤ Add a larger air receiver downstream to increase buffer capacity.
➤ Set the setpoint pressure as described in the SIGMA CONTROL operating instructions.

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 7 Initial Start-up
7.10 Changing the display language

7.10 Changing the display language

The controller can display text messages in several languages. The display language can be changed
first during initial start-up.
A label explains how this is done with the help of icons.

Fig. 16 Label: Changing the display language

1 If required: 5 Press «Enter» to enter language selection.
Unlatch the EMERGENCY STOP button. 6 Press the «UP» or «DOWN» keys as often as
2 If required: necessary to reach the required language.
Acknowledge alarm message. 7 Press «enter» to select the language.
3 Depress the «escape» key for 5 seconds to 8 Depress the «escape» key for 5 seconds to
change to the main menu. change to the main menu.
4 Press the «UP» key 8 times.

➤ Change the display language on SIGMA CONTROL as required.

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 8 Operation
8.1 Switching On and Off

8 Operation
8.1 Switching On and Off
Always switch the machine on with the «ON» key and off with the «OFF» key.
A power supply disconnecting device has been installed by the user.

Fig. 17 Switching on and off

1 Machine ON LED (green) 3 «OFF» key
2 «ON» key 8 Controller ON LED (green)

8.1.1 Switching on
Precondition No personnel are working on the machine,
all access doors and panels are closed and secure.

1. Switch on the power supply disconnecting device.

After the controller has carried out a self-test, the green Power ON LED lights continuously.
2. Press the «ON» key.
The green Machine ON LED lights continuously.
If a power failure occurs, the machine is not prevented from automatic re-starting.
It can start automatically again as soon as power is restored.

Result The compressor motor starts as soon as system pressure is lower than the setpoint pressure (cut-
out pressure).

8.1.2 Shutdown
1. Press the «LOAD/IDLE» key.
The machine switches to IDLE and the IDLE LED flashes.
2. After allowing the machine to IDLE for 20 seconds:
press the «OFF» key.
The Machine ONLED extinguishes.
The machine is ready for operation. The machine can now be started again.

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 8 Operation
8.2 Switching Off in an Emergency and Switching On again

3. Switch off and lock out the power supply disconnecting device.
The machine is switched off and isolated from the mains supply. The Controller ONLED extin‐
guishes.

8.2 Switching Off in an Emergency and Switching On again

The EMERGENCY STOP pushbutton is located below the control panel.

Fig. 18 Switching off in an emergency

9 EMERGENCY STOP pushbutton

Shutdown

➤ Press the EMERGENCY STOP pushbutton.

The pushbutton remains latched in.
The compressor's pressure system is vented and the machine is prevented from automatically
re-starting.

Switching on

Precondition The fault has been rectified

1. Turn the EMERGENCY STOP pushbutton in the direction of the arrow to unlatch it.
2. Press the reset key to reset any alarm messages.
The machine can now be started again.

8.3 Remote On and Off Switching

Precondition A remote control device is linked.

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 8 Operation
8.4 Switching On and Off with the Clock

Fig. 19 Switching on and off in remote

1 «remote control» key
2 remote control LED

1. Attach an easily seen notice that warns of remote machine operation.

DANGER!
This machine is remotely controlled and can start automatically at any time.

Tab. 49 Machine identification

2. Label the starting device in the remote control centre as follows:

DANGER!
➤ Before starting, make sure that no one is working on the machine and that it can be safely started.

Tab. 50 Remote control identification

3. Press the «remote» key.

The remote LED lights. The machine can be remotely controlled.

8.4 Switching On and Off with the Clock

Precondition The clock is programmed.

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 8 Operation
8.5 Acknowledging Alarm and Warning Messages

Fig. 20 Switching on and off with the clock

1 «clock» key
2 clock key

1. Attach an easily seen notice warning of time-controlled operation:

DANGER!
This machine is time-controlled and can start automatically at any time.

Tab. 51 Machine identification

2. Press the «clock» key.

The clock LED lights. The machine is switched on and off by the clock.

8.5 Acknowledging Alarm and Warning Messages

Messages are displayed on the "new value" principle:
■ Message received: LED flashes
■ Message acknowledged: LED lights
■ Message gone: LED extinguished

or

■ Message received: LED flashes

■ Message gone: LED flashes
■ Message reset: LED extinguished

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 8 Operation
8.5 Acknowledging Alarm and Warning Messages

Fig. 21 Acknowledging/resetting messages

10 warning (yellow) LED
11 alarm (red) LED
12 «acknowledge/reset» key

Alarm message

Precondition Fault has been rectified

➤ Reset the message with the «acknowledge/reset» key.

alarm LED extinguishes.
The machine is now ready to start again.

Warning message

Precondition The danger of an alarm is eliminated.

Maintenance has been carried out

➤ Reset the message with the «acknowledge/reset» key.

warning LED extinguishes.

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 9 Fault Recognition and Rectification
9.1 Basic Information

9 Fault Recognition and Rectification

9.1 Basic Information
The following tables are intended to assist in locating faults.

There are three types of fault:

■ Alarm: red LED flashes - see chapter 9.2.
■ Warning: yellow LED flashes - see chapter 9.3.
■ Other faults: no indication - see chapter 9.4.

The messages valid for your machine are dependent on the controller and individual equipment.
1. Do not attempt fault removal measures other than those given in this manual.
2. In all other cases:
have the fault rectified by an authorised KAESER service representative.

9.2 Alarm messages (machine shut-down)

Message Possible cause Remedy
blowoff prot. ↥ The activating pressure of the pressure Change the oil separator cartridge
relief valve on the oil separator tank has Open the shut-off valve in the vent‐
been exceeded. ing line.
AI1 open cct. Analog input open circuit. Check line and connections.
AI2 open cct. Short to earth.
AI1 short cct. The connection between the sensor Check line and connections.
AI2 short cct. and the analog input is shorted.
AI3/AI4 error Line-break between the analog input Check line and connections.
and the sensor.
Short circuit to earth.
AI5 open cct. Analog input open circuit. Check line and connections.
AI6 open cct. Short to earth.
AI5 short cct. The connection between the sensor Check line and connections.
AI6 short cct. and the analog input is shorted.
AI7/AI8 error Line-break between the analog input Check line and connections.
and the sensor.
Short circuit to earth.
model Machine model uncertain Call KAESER Service.
PD T ↧ Package discharge (PD) temperature Call KAESER Service.
too low.
PD T ↥ Package discharge (PD) temperature Check the cooling oil level
too high. Clean the cooler.
Check the fan motor.
DO0.6/DO0.7 I ↥ Short circuit in the line between the dig‐ Check line and connections.
ital output and the consumer.

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 9 Fault Recognition and Rectification
9.2 Alarm messages (machine shut-down)

Message Possible cause Remedy

DO1.6/DO1.7 I ↥ Short circuit in the line between the dig‐ Check line and connections.
ital output and the consumer.
airend rotation The drive motor is turning in the wrong Swap phase lines L1 and L2.
direction.
ext. message 0 Customer specific: –
ext. message 1 no details possible.
ext. message 2
ext. message 3
ext. message 4
ext. message 5
FC Frequency converter faulty. Call KAESER Service.
back press. stop Back pressure in the oil separator tank Check venting line.
caused by defective venting.
back press. run Drive belts or coupling broken. Drive belts:
Replace drive belts.
Coupling:
Call KAESER Service.
HT cell Fault in the high tension cell. Call KAESER Service.
no press.buildup The machine produces no compressed Check the machine for leaks.
air. Check coupling/V-belts
The working pressure does not rise Call KAESER Service.
above 3.5 bar within a default period.
condensatedrain The condensate drain is defective. Check the condensate drain.
coolingwater low Cooling water pressure is too low. Check cooling water supply.
Cooling water stop valve:
Check open/closed.
RD condens.drain Condensate drain faulty. Check the condensate drain.
RD p ↥ The pressure switch for the refrigerant Keep ambient conditions within
compressor has activated. specified limits.
Clean the refrigerant condenser.
Clean the cooler.
RD T ↧ Temperature in refrigeration dryer too Call KAESER Service.
low.
fan M2 I ↥ Overload shut-down of the first fan mo‐ Investigate cause of shut-down.
tor. Reset overload protection cut-out.
Call KAESER Service.
fan M3 I ↥ Overload shut-down of the second fan Investigate cause of shut-down.
motor. Reset overload protection cut-out.
Call KAESER Service.
fan M4 I ↥ Overload shut-down of the third fan mo‐ Investigate cause of shut-down.
tor. Reset overload protection cut-out.
Call KAESER Service.
fan M7 I ↥ Overload shut-down of the control cab‐ Investigate cause of shut-down.
inet fan motor. Call KAESER Service.

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 9 Fault Recognition and Rectification
9.2 Alarm messages (machine shut-down)

Message Possible cause Remedy

motor I ↥ Overload shut-down of the compressor Investigate cause of shut-down.
drive motor. Change the oil separator cartridge.
Call KAESER Service.
motor T ↥ Drive motor overheated. Clean the motor.
Keep ambient conditions within
specified limits.
motor bearings Drive motor bearings overheated. Re-grease the motor bearings.
Call KAESER Service.
mains cont. on? Mains contactor not pulling in. Check mains contactor and wiring.
mains cont. off? Mains contactor not dropping out. Check mains contactor and wiring.
mains voltage ↧ 2nd. power failure. Check power supply voltage.
Check the door interlock switch.
mains monitor Fault in mains power supply. Have the mains power supply
checked.
Emergency stop EMERGENCY STOP pushbutton Unlatch the pushbutton.
pressed.
OS dp ↥ Oil separator cartridge clogged. Change the oil separator cartridge.
OS T ↥ Maximum air temperature at the oil sep‐ Check the line to the trip relay.
arator tank outlet is exceeded.
oil p ↓ The machine cannot switch to LOAD Check the oil circulation.
until the minimum oil pressure is Check the pressure switch, line
reached. and connection.
p-switch Customer specific: –
no details possible.
pRV ↥ The activating pressure of the pressure Change the pressure relief valve.
relief valve on the oil separator tank has
been exceeded.
oil content ↑ The oil content limit for pure air has Change the oil separator cartridge.
been exceeded.
SIGMA CONTROL T ↥ The maximum permissible Keep ambient conditions within
SIGMA CONTROL housing tempera‐ specified limits.
ture has been exceeded. Control cabinet:
Check filter mats and fan.
Softstart Fault in the soft start equipment. Call KAESER Service.
start T ↧ Airend discharge temperature (ADT) Keep ambient conditions within
too low. specified limits.
Ambient temperature <+2 °C
T-switch Customer specific: –
no details possible.
ADT ↓ The airend discharge temperature Call KAESER Service.
(ADT) did not reach the minimum value
required within the specified time.

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 9 Fault Recognition and Rectification
9.3 Warning messages (yellow LED lights)

Message Possible cause Remedy

ADT ↥ Maximum permissible airend discharge Keep ambient conditions within
temperature (ADT) exceeded. specified limits.
Clean the cooler.
Check the cooling oil level.
ADT dT/dt ↥ Airend discharge temperature (ADT) Check the cooling oil level.
rising too quickly. Call KAESER Service.
access doors Door open / interlocked panel removed Fit and secure all panels and close
while the machine is running. access doors.

Tab. 52 Alarm messages and measures

9.3 Warning messages (yellow LED lights)

Message Possible cause Remedy
blowoff prot. ↑ The activating pressure of the pres‐ Change the oil separator cartridge.
sure relief valve will soon be Open the shut-off valve in the venting line.
reached.
bus alarm The bus link from the Profibus DP Check bus highway and plug.
interface is interrupted.
PD temperature ↓ Package discharge (PD) tempera‐ Call KAESER Service.
ture too low.
PD temperature ↑ Package discharge (PD) tempera‐ Clean the cooler.
ture too high. Check the cooling oil level.
DO test The 'controller outputs' test function Stop the 'controller output' mode.
is activated.
restart inhibit Too frequent manual on and off Do not exceed the maximum number of
switching. motor switchings per hour when manual on/
off switching.
elect. equip. h ↥ The maintenance interval for Carry out the check and reset the mainte‐
checking electrical equipment and nance interval counter.
wiring has expired.
error: FEPROM Internal controller memory error. Call KAESER Service.
error: RS 485–PP Wrong configuration or transmis‐ Check the link/interface connections be‐
sion error. tween the two controllers.
Check maximum cable length and screen‐
ing.
1 master and 1 slave configured.
error SMS SMS can not be sent. Call KAESER Service.
ext. message 0 Customer specific: –
ext. message 1 no details possible.
ext. message 2
ext. message 3
ext. message 4
ext. message 5

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 9 Fault Recognition and Rectification
9.3 Warning messages (yellow LED lights)

Message Possible cause Remedy

FC AI1 fault SFC machine: Call KAESER Service.
Network pressure sensor on AI1
defective.
FC MM service SFC machine: Deactivate the service mode as soon as the
Frequency converter service frequency converter settings are comple‐
mode. ted.
FC mains SFC machine: Check power supply.
Frequency converter power supply
failed.
annual maint Last maintenance was 1 year ago. Carry out the necessary maintenance and
reset the corresponding maintenance inter‐
val counter.
no press.buildup The compressor cannot build-up to Check for air leaks.
working pressure. Check the value for internal pressure given
in the <analog data> menu against the
reading on the oil separator tank pressure
gauge.
condensatedrain The condensate drain is defective. Check the condensate drain and drain line.
RD condens.drain Refrigeration dryer: Check the condensate drain.
The condensate drain is defective.
RD p ↓ Refrigeration dryer: Call KAESER Service.
Pressure in refrigerant circuit too
low
Pressure switch activated.
RD p ↥ Refrigeration dryer: Keep ambient conditions within specified
Pressure in refrigerant circuit too limits.
high Clean the refrigerant condenser.
Pressure switch activated.
Check the fan motor.
Call KAESER Service.
RD T ↓ Refrigeration dryer: Call KAESER Service.
Compressed air temperature too
low.
RD T ↑ Temperature in the refrigeration Ensure adequate ventilation.
dryer too high. Clean the refrigerant condenser.
Clean the cooler.
Install an extractor fan.
bearing.maint. h ↥ The maintenance interval for re- Re-grease the motor bearings.
greasing the bearings has expired.
ext.load signal? Uncertain external load signal: Check settings of the external controller.
The high cut-out pressure was ex‐ Take into account pressure drops across
ceeded. filters and dryer.
The external load control has not
switched to idle (off load).
air filter dp ↑ Air filter clogged. Carry out air filter maintenance
air filter dp ↥ Air filter clogged. Carry out air filter maintenance

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 9 Fault Recognition and Rectification
9.3 Warning messages (yellow LED lights)

Message Possible cause Remedy

air filter h ↥ Maintenance interval for air filter Check the air filter.
check has elapsed.
modem problem SIGMA CONTROL does not recog‐ Check the link between
nise the modem. SIGMA CONTROL and the modem.
motor T ↑ Drive motor overheating. Clean the motor.
Keep ambient conditions within specified
limits.
motor bearings Drive motor bearing defective. Call KAESER Service.
motor starts /h ↥ The permissible number of motor Extend the idle period.
starts was exceeded in the last Increase the capacity of air receiver.
60 minutes.
Increase the cross-section of piping be‐
tween compressor and air receiver.
motor starts /d ↥ The permissible number of motor Extend the idle period.
starts was exceeded in the last Increase the capacity of air receiver.
24 hours.
Increase the cross-section of piping be‐
tween compressor and air receiver.
bearingchange h ↥ The maintenance interval for Have the motor bearings checked by an
checking the motor bearings has authorized KAESER Service Technician.
expired.
system press. ↓ Network pressure has fallen below Check air demand.
the set 'low' value. Check cable runs and sensor connections.
Air consumption too high. Check the 'sys.press. low' warning setting.
system press. ↑ Network pressure is above the Check for air leaks.
"sys.press. high" value. Check the 'sys.press. high' warning setting.
Check whether the machine switches to
LOAD.
mains voltage ↓ 1. Power supply failure: Check power supply.
Machine was re-started automati‐ Check the door interlock switch.
cally.
separator dp ↑ The pressure drop across the oil Change the oil separator cartridge.
separator cartridge has risen.
Oil separator cartridge clogged.
separator h ↥ The interval for the next oil separa‐ Change the oil separator cartridge.
tor cartridge check has expired.
oil filter dp ↑ The pressure drop across the oil fil‐ Change the oil filter
ter has risen.
Oil filter clogged.
oil filter h ↥ The interval for the next oil filter Change the oil filter.
check has expired.
oil level ↓ Cooling oil level too low. Top up the cooling oil.
oil T ↓ Cooling oil temperature too low. Check temperature switch, line and con‐
nection.
Check the oil circulation.
Increase room temperature.

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 9 Fault Recognition and Rectification
9.3 Warning messages (yellow LED lights)

Message Possible cause Remedy

oil change h ↥ The interval for the oil change has Change the cooling oil
expired.
p-switch Customer specific: –
no details possible.
buffer battery Data retention battery is almost dis‐ Change the battery.
charged.
error: RAM Internal RAM defective. Call KAESER Service.
oil content ↑ The oil content limit for pure air will Check the scavenge tube in the oil separa‐
soon be reached. tor cartridge.
Check the dirt trap strainer in the scavenge
line.
Check air treatment upstream of the meas‐
uring point.
V-belt tension Belt tension is too low. Re-tension drive belts.
blt.coup.insp. h ↥ The maintenance interval for V-belt Carry out a visual check.
tension / coupling inspection has Re-tension drive belts.
expired.
blt.coup.chng. h ↥ The maintenance interval for Drive belts:
changing the belts/coupling has ex‐ Replace the drive belts.
pired. Coupling:
Call KAESER Service.
start T ↓ ↓ The airend temperature is too low Keep ambient conditions within specified
(<−10 °C) for the machine to be op‐ limits.
erated.
start T ↓ The airend temperature is too low Keep ambient conditions within specified
(<+2 °C). limits.
T-switch Customer specific: –
no details possible.
TRAP interrupt System message: Call KAESER Service.
TRAP interrupt
ADT ↑ Airend discharge temperature has Clean the cooler.
almost reached maximum. Check the cooling oil level.
Replace the oil filter.
Ensure adequate ventilation.
Keep surrounding temperature within rec‐
ommended limits.
access doors Doors opened with the machine Close access doors.
stopped.

Tab. 53 Warning messages

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 9 Fault Recognition and Rectification
9.4 Other Faults

9.4 Other Faults

Fault Possible cause Remedy
Machine runs but produces no Inlet valve not opening or only Call KAESER service represen‐
compressed air. opening partially. tative.
Venting valve not closing. Call KAESER service represen‐
tative.
Leaks in the pressure system. Check pipework and connec‐
tions for leaks and tighten any
loose fittings.
Air consumption is greater than Check the air system for leaks.
the capacity of the compressor. Shut down the consumer(s).

Hose coupling or maintenance Remove coupling or mainte‐

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

Tab. 54 Other faults and actions

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 10 Maintenance
10.1 Safety

10 Maintenance
10.1 Safety
Follow the instructions below to ensure safe machine maintenance.
Warning instructions are always given before a potentially dangerous task.

Basic safety instructions

1. Follow the instructions in chapter 3 "Safety and Responsibility".

2. Maintenance work may only be carried out by authorized personnel.
3. Before switching on, make sure that:
■ no one is working on the machine,
■ all access doors and panels are closed and secure.

Working on live components

1. Have work on electrical equipment carried out by authorized electricians only.

2. Switch off and lock out the power supply disconnecting (isolating) device and check that no volt‐
age is present.
3. Check that there is no voltage on floating relay contacts.

Working on pressure systems

1. Close shut-off valves or otherwise isolate the machine from the compressed air system to ensure
that no compressed air can flow back into the machine.
2. Vent all pressurized components and chambers completely.
3. Check all hose couplings in the compressed air system with a hand-held pressure gauge to en‐
sure that they all read 0 bar.
4. Do not open or dismantle any valves.

Working on the drive system

1. Switch off and lock out the power supply disconnecting (isolating) device and check that no volt‐
age is present.
2. Do not open the cabinet while the machine is switched on.

Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.5.

10.2 Maintenance Schedule

10.2.1 Logging maintenance work
The maintenance intervals given are those recommended for average operating conditions.
➤ Maintenance tasks should be carried out more frequently where operating conditions are
unfavourable (e.g. dusty atmosphere) or when the equipment is in constant use.
➤ Adjust the maintenance intervals with regard to local installation and operating conditions.

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 10 Maintenance
10.2 Maintenance Schedule

➤ Keep a log of all maintenance and repair work.

This enables the frequency of individual maintenance tasks and deviations from our recommen‐
dations to be determined.

Further information A prepared list is provided in chapter 10.20.

10.2.2 Resetting maintenance interval counters

According to the way a machine is equipped, sensors and/or maintenance interval counters monitor
the operational state of major components. Necessary maintenance tasks are displayed on
SIGMA CONTROL.
Maintenance interval counters count down the operating hours to the next maintenance task.
Reset the counter to the original value once the task has been carried out.

Precondition Maintenance carried out,

service message acknowledged and
password level 4 activated.

1. Select the appropriate entry in the "Maintenance" menu.

2. Select 'reset' and 'y' and confirm with the «enter» key.

Further information Detailed information can be found in the SIGMA CONTROL operating instructions.

10.2.3 Regular maintenance tasks

The table below lists maintenance tasks required.
➤ Take note of the controller's service messages and carry out tasks punctually, taking ambient
and operating conditions into account.

Interval Maintenance task See chapter

Weekly Check the cooling oil level. 10.13
Cooler: 10.3
Clean or renewing the filter mats.
Control cabinet: 10.4
Clean or renewing the filter mats.
Up to 1,000 h Clean the cooler. 10.5
Indicator: Change the air filter element. 10.8
SIGMA CONTROL Maintain the motor bearings. 10.9
Check the coupling. 10.10
Indicator: Change the oil filter. 10.17
SIGMA CONTROL
At least annually
Indicator: Change the oil separator cartridge. 10.18
SIGMA CONTROL
At the latest every 3 years
Variable, see table 56 Change the cooling oil. 10.16
h = operating hours

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 10 Maintenance
10.2 Maintenance Schedule

Interval Maintenance task See chapter

Annually Check the pressure relief valve. 10.11
Check the overheating safety shutdown function. 10.12
Check the cooler for leaks. 10.5
Maintain the water-cooling system. 10.6
Maintain the heat recovery system. 10.7
Check that all electrical connections are tight. –
h = operating hours

Tab. 55 Regular maintenance tasks

10.2.4 Cooling Oil: Change Interval

Duty cycles and ambient conditions are important criteria for the number and length of the change
intervals.
KAESER Service will support you in determining suitable intervals and provide information on
the possibilities of oil analysis.

➤ Please observe national regulations regarding the use of cooling oil in oil-injected rotary screw
compressors.
➤ Check operating conditions and adjust intervals as necessary; log the results in table 56 for future
reference.

Maximum permissible oil change interval

[operating hours/year]
SIGMA FLUID Favourable operating Unfavourable operat‐ My operating condi‐
conditions* ing conditions tions
S-460 6 000**/2 4 000/1
MOL 3 000/1 2 000/1
FG–460 3 000/1 2 000/1
FG–680 3 000/1 2 000/1
* Cool to moderate ambient temperatures, low humidity, high duty cycle
** Changing intervals of >6000 operating hours are not permissible without an oil analysis.

Tab. 56 Cooling oil changing intervals

10.2.5 Regular service tasks

The table below lists necessary service tasks.
➤ Only an authorized KAESER Service Technician should carry out service work.
➤ Carry out service tasks punctually taking ambient and operating conditions into account.

Interval Service task

Up to 12,000 h Check the valves
h = operating hours

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 10 Maintenance
10.3 Cleaning or Renewing the Cooling Air Filter Mat

Interval Service task

Up to 36,000 h Drive motor:
At the latest every 8 years Have the bearings checked.
Fan motor:
Have the bearings checked.
Have hose lines checked.
h = operating hours

Tab. 57 Regular service tasks

10.3 Option K3
Cleaning or Renewing the Cooling Air Filter Mat
The filter mat help to keep the cooler clean. If the filter mat is clogged, adequate cooling of the com‐
ponents is no longer ensured.

Material Warm water and household detergent

Spare parts (as required)

Precondition The machine is switched off.

Fig. 22 Cooling air filter mat

1 Cooling air filter mat
2 Retaining frame
3 Fixing

Removal

1. Open the fixing 3

by turning 90° anti-clockwise with a screwdriver.
2. Remove the frame 2 .

Cleaning

➤ Renew the mat if cleaning is not possible or has already been carried out five times.

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 10 Maintenance
10.4 Cleaning or Replacing the Control Cabinet Filter Mats

➤ Beat the mat 1 or use a vacuum cleaner to remove loose dirt.

If necessary, wash the mat in lukewarm water (about 40 °C) and household detergent then rinse
thoroughly.

Refitting

➤ Replace the frame and close the fixings.

Use a screwdriver to turn the fixings 90° clockwise until they latch.

10.4 Cleaning or Replacing the Control Cabinet Filter Mats

Filter mats protect the control cabinet from ingress of dirt. If the filter mats are clogged, adequate
cooling of the components is no longer ensured. In such a case, clean or replace the filter mats.

Material Warm water and household detergent

Spare parts (as required)

Precondition The power supply disconnecting (isolating) device is switched off,

the disconnect device is locked in the off position,
a check has been made that no voltage is present.
The machine has cooled down.

Fig. 23 Control cabinet ventilation grill

1 Ventilation grill
2 Filter mat

1. Carefully remove the ventilation grill 1 and take out the filter mat 2 .
2. Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash with lukewarm
water and household detergent.
3. Change the filter mat if cleaning is not possible or if the change interval has expired.
4. Lay the filter mat in the frame and latch in the ventilation grill.

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 10 Maintenance
10.5 Cooler maintenance

10.5 Option K1
Cooler maintenance
Regular cleaning of the cooler ensures reliable cooling of the machine and the compressed air. The
frequency is mainly dependent on local operating conditions.
A leaking cooler results in loss of cooling oil and compressed air.

Material Brush and vacuum cleaner

Face mask (as required)

Precondition The supply disconnecting device is switched off,

the device is locked off,
a check has been made that no voltage is present.
The machine has cooled down.

Fig. 24 Cooler cleaning

1 Cooler
2 Brush

Cooler cleaning

Do not use sharp objects to clean the cooler. It could be damaged.

Avoid creating clouds of dust.
➤ Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt.
The air and oil coolers can no longer be properly cleaned?
➤ Have stubborn clogging removed by an authorized KAESER Service Technician.

Check the cooler for leaks

➤ Can cooling oil be seen to be leaking?

Is a cooler leaking?
➤ Have the defective cooler repaired immediately by KAESER Service.

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 10 Maintenance
10.6 Water-cooling Maintenance

10.6 Option K2
Water-cooling Maintenance
Cooler clogging causes overheating and machine damage.
➤ Observe the airend discharge temperature to detect any tendency to rise.
Check the cooler regularly for leaks and contamination. Frequency of checking is dependant on the
characteristics of the cooling water.

Precondition The power supply disconnecting device is switched off.

The disconnecting device is locked in the off position.
A check has been made that no voltage is present.

Check for leaks

Pressure in the cooling oil circuit is generally higher than that in the cooling water system. If a leak
occurs, oil will run into the cooling water.
1. Check the cooler visually for leaks.
2. Have an authorised KAESER Service Technician check the heat exchanger for internal leaks at
least once a year.

Cleaning

➤ An authorised KAESER Service Technician should clean the cooler when the airend discharge
temperature is 10 °C above the annual average.

10.7 Option W1/W2/W3

Heat Recovery System Maintenance
Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.
Check the heat exchanger regularly for leaks and contamination. Frequency of checking is dependant
on the characteristics of the heat transfer medium.
➤ Monitor the pressure in the heat transfer medium to detect any pressure drop.

10.7.1 Option W1
External heat recovery
➤ Have the external heat recovery system checked annually by KAESER Service.

10.7.2 Option W2/W3

Internal heat recovery
Precondition The power supply disconnecting device is switched off.
The disconnecting device is locked in the off position.
A check has been made that no voltage is present.

Leakage

Pressure in the cooling oil circuit is generally higher than that in the heat recovery system. If a leak
occurs, oil will run into the heat transfer medium.

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 10 Maintenance
10.8 Change the air filter

1. Check the heat exchanger visually for leaks.

2. Have an authorised KAESER Service Technician check the heat exchanger for internal leaks at
least once a year.

Contamination

➤ Have an authorised KAESER Service Technician clean the heat exchanger as soon as a pressure
drop in the heat transfer medium is detected.

10.8 Change the air filter

Check that all sealing surfaces match each other. The use of an unsuitable air filter element
can permit dirt to ingress the pressure system and cause damage to the machine.
Do not clean the air filter element. A damaged air filter element can permit dirt to ingress the
pressure system and cause damage to the machine.

Material Spares

Precondition The supply disconnecting device is switched off,

the device is locked off,
a check has been made that no voltage is present.
The machine has cooled down.

Fig. 25 Air filter maintenance

2 Air filter element 5 Cover plate
4 Nut 6 Access panel

1. Remove the access panel 6 .

2. Remove the cover plate 5 .
3. Unscrew the nut 4 and remove the filter element.
4. Clean all parts and sealing surfaces.
5. Insert the new element and secure with the nut 4 .
6. Screw the cover plate 5 onto the machine.
7. Close all access doors and replace all enclosure panels.
8. Switch on the power supply and reset the maintenance interval counter.

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 10 Maintenance
10.9 Motor maintenance

10.9 Motor maintenance

Use only the high temperature grease ESSO UNIREX N3 for the motor bearings. Bearing dam‐
ages caused by the use of other brands of grease are excluded from the warranty.

Material Bearing grease ESSO UNIREX N3

Cleaning cloths

Fig. 26 Drive motor maintenance

1 Grease nipple (drive motor)
2 Grease nipple (fan motor K1)

Drive motor

Nipples for re-greasing the motor bearings are located on the outside of the machine.
The lines to the bearings are factory-filled with grease.
Apply the quantity of grease as stated on the motor nameplate.

Precondition Motor running

1. Clean the nipple 1 with a cloth before greasing.

2. Grease both bearings with a grease gun.
3. Reset the maintenance interval counter.

Option K1 Fan motor

Nipples for re-greasing the motor bearings are located on the outside of the machine.
The lines to the bearings are factory-filled with grease.
Apply the quantity of grease as stated on the motor nameplate.

Precondition Motor running

1. Clean the nipple 2 with a cloth before greasing.

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 10 Maintenance
10.10 Checking the coupling

2. Grease both bearings with a grease gun.

3. Reset the maintenance interval counter.

Option K2 Fan motor

➤ Have the fan motor bearings checked by a KAESER Service Technician during the course of a
visit.

10.10 Checking the coupling

A defective coupling is recognisable by:
■ noisy running,
■ surface cracks,
■ colour change.

WARNING
Danger of injury from rotating coupling!
➤ Never switch the machine on without the safety screen in place over the coupling.

Fig. 27 Checking the coupling

1 Safety screen
2 Coupling

Check for uneven or noisy running.

Precondition The machine is running

➤ Check the coupling for noisy or uneven running.

Make a visual check for damage.

Precondition The supply disconnecting device is switched off,

the device is locked off,
a check has been made that no voltage is present.
The machine has cooled down.

1. Remove the securing screws and take off the safety screen.

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 10 Maintenance
10.11 Checking the Pressure Relief Valve

2. Turn the coupling my hand and look for damage or colour change.
3. Refit the safety screen.
4. Close all access doors and replace all enclosure panels.
Has the coupling cracks or colour changes?
➤ Have a damaged coupling changed by an authorised KAESER Service Technician.

10.11 Checking the Pressure Relief Valve

In order to check the pressure relief valve, the machine's working pressure is raised above the acti‐
vating pressure of the valve.
Blowoff protection and air system pressure monitoring are switched off during the test.
➤ Follow the detailed description of this procedure in the SIGMA CONTROL operating in‐
structions.
➤ Never operate the machine without a fully functioning pressure relief valve.

Precondition The machine is switched off.

Password level 4 is activated.

WARNING
The pressure relief valve blows off.
Excessive noise is caused when the pressure relief valve blows off.
There is danger of scalding from hot oil.
There is danger of injury from bursting components and compressed air.
➤ Close all access doors; replace and secure all removable panels.
➤ Wear ear and eye protection.
➤ Abort the test if the working pressure rises 10% above the activating pressure of the valve.

1. Close the user's shut-off valve between the machine and the air system.
2. Read off the activating pressure on the valve.
(the activating pressure is usually to be found at the end of the part identification)
3. Observe the display of pressure on SIGMA CONTROL and call up the test function.
4. Stop the test as soon as the pressure relief valve blows off or working pressure rises to 10 %
above the activating pressure of the pressure relief valve.
5. If necessary, vent the machine and replace the defective pressure relief valve.
6. Deactivate the test function.
7. Open the user's shut-off valve between the machine and the air system.

10.12 Checking the Excess Temperature Safety Shutdown Function

The machine should shut down if the airend discharge temperature reaches a maximum of 110 °C.
➤ Check the safety shutdown function as described in the SIGMA CONTROL operating instructions.
The machine does not shut down?.
➤ Have the safety shutdown function checked by an authorized KAESER service represen‐
tative.

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 10 Maintenance
10.13 Checking the cooling oil level

10.13 Checking the cooling oil level

The oil level indicator in frequency-controlled compressors (SFC) is only accurate when the
machine is running at or near maximum speed.
The lower the pressure at the compressed air outlet, the higher the speed. The
SIGMA CONTROL displays this value.

Precondition The machine has been running at least 5 minutes under LOAD.

Fig. 28 Checking the cooling oil level

1 Minimum oil level
2 Maximum oil level
3 Optimum level

WARNING
Danger of burning from hot surfaces!
➤ Wear long-sleeved clothing and protective gloves.

➤ Check the oil level with machine running.

Result Top up when the indicator shows minimum level.

10.14 Venting the Machine (depressurizing)

The machine must be isolated from the air system and completely vented before undertaking
any work on the pressure system.

The oil circulation vents automatically as soon as the machine is stopped.

Venting takes place in three stages:

■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.

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 10 Maintenance
10.14 Venting the Machine (depressurizing)

Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.

Precondition The power supply disconnecting (isolating) device is switched off,

the disconnect device is locked in the off position,
a check has been made that no voltage is present.

WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
➤ Vent all pressurized components and chambers completely.

Fig. 29 Venting the machine

1 Hose coupling (air cooler venting) 7 Shut-off valve
2 Pressure gauge A Shut-off valve open
3 Hose coupling (oil separator tank venting) B Shut-off valve closed
6 Male hose coupling 8 Maintenance hose

Isolate the machine from the air system.

➤ Close the user's shut-off valve between the machine and the air system.
If no shut-off valve is provided, the complete air system must be vented.

Venting the oil separator tank

WARNING
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

➤ Check that the oil separator tank pressure gauge reads 0 bar.

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74 DSD SIGMA CONTROL 9_6977 00 E
 10 Maintenance
10.15 Topping up the Cooling Oil

After automatic venting the pressure gauge does not read zero?
➤ Make sure that the shut-off valve is closed or that the complete air system is vented.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not reduce the oil separator tank pressure gauge to 0 bar, call an
authorized KAESER service representative.

Manually venting the air cooler

After shutting down the compressor and venting the oil separator tank, the machine is still under
pressure from the air system or the section from the shut-off valve to the minimum pressure/
check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .

10.15 Topping up the Cooling Oil

The machine must be isolated from the air system and completely vented before undertaking
any work on the pressure system.

Material The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.

Precondition The power supply disconnecting (isolating) device is switched off,

the disconnect device is locked in the off position,
a check has been made that no voltage is present.

Fig. 30 Topping up the Cooling Oil

1 Hose coupling (air cooler venting) 6 Male hose coupling
2 Pressure gauge 7 Shut-off valve
3 Hose coupling (oil separator tank venting) A Shut-off valve open
4 Oil filler with plug B Shut-off valve closed
5 Cooling oil level indicator 8 Maintenance hose

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 10 Maintenance
10.15 Topping up the Cooling Oil

1. Vent the machine as described in section 10.15.1.

2. Fill with cooling oil and test run as described in section 10.15.2.

10.15.1 Venting the machine (depressurizing)

The oil circulation vents automatically as soon as the machine is stopped.

Venting takes place in three stages:

■ Isolate the compressor from the air system.
■ Vent the oil separator tank.
■ Manually vent the air cooler.

WARNING
Compressed air!
Compressed air and devices under pressure can injure or cause death if the contained energy is
released suddenly or uncontrolled.
➤ Vent all pressurized components and chambers completely.

Isolate the machine from the air system.

➤ Close the user's shut-off valve between the machine and the air system.
If no shut-off valve is provided, the complete air system must be vented.

Venting the oil separator tank

WARNING
Escaping oil mist is damaging to health.
➤ Do not direct the maintenance hose at persons while venting.
➤ Do not inhale the oil mist.

➤ Check that the oil separator tank pressure gauge reads 0 bar.
After automatic venting the pressure gauge does not read zero?
➤ Make sure that the shut-off valve is closed or that the complete air system is vented.
➤ With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 3 .
➤ Slowly open the shut-off valve 7 to release pressure.
➤ Disconnect the male hose fitting 6 and close the shut-off valve 7 .
➤ If manual venting does not reduce the oil separator tank pressure gauge to 0 bar, call an
authorized KAESER service representative.

Manually venting the air cooler

After shutting down the compressor and venting the oil separator tank, the machine is still under
pressure from the air system or the section from the shut-off valve to the minimum pressure/
check valve.
1. With the shut-off valve closed, insert the male hose fitting 6 into the hose coupling 1 .
2. Slowly open the shut-off valve 7 to release pressure.
3. Disconnect the male hose fitting 6 and close the shut-off valve 7 .

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 10 Maintenance
10.16 Changing the cooling oil

10.15.2 Topping up with cooling oil and trial run

Topping up the cooling oil

A sticker on the oil separator tank specifies the type of oil used.

CAUTION
The machine could be damaged by unsuitable oil.
➤ Never mix different types of oil.
➤ Never top up with a different type of oil to that already used in the machine.

1. Slowly unscrew the filler plug 4 .

2. Top up to bring the oil to the correct level.
3. Replace the filler plug's sealing ring if necessary and screw the plug into the filler neck.

Starting the machine and carrying out a trial run

1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the air system.
3. After about 10 minutes, check the oil level again and top up if necessary.
4. Switch off the machine and visually check for leaks.

10.16 Changing the cooling oil

The machine must be isolated from the compressed air network and completely vented before
undertaking any work on the pressure system.

Drain the oil completely from the following components:

■ Oil separator tank
■ Oil cooler
■ Airend
■ Internal heat recovery system (option W1/W2/W3)

➤ Always change the oil filter and oil separator cartridge when changing the oil.
➤ Contact KAESER Service if condensate is detected in the cooling oil. It is necessary to
adjust the airend discharge temperature to suit operating conditions.
Compressed air helps to expel the oil. This compressed air can be taken either from the compressor
itself or from an external source.

An external source of compressed air is necessary in the following cases:

■ The machine is not operational.
■ The machine is to be restarted after a long period of standstill.

Material Cooling oil

Cooling oil receptacle
The maintenance hose with hose coupling and shut-off valve needed for venting is stowed beneath
the oil separator tank.

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10.16 Changing the cooling oil

WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.

Fig. 31 Changing the cooling oil, oil separator tank

1 Hose coupling (air cooler venting) A Shut-off valve open
2 Pressure gauge B Shut-off valve closed
3 Hose coupling (oil separator tank venting) 8 Maintenance hose
4 Oil filler port with plug 9 Hose coupling (oil drain)
5 Cooling oil level indicator 10 Shut-off valve (venting line)
6 Male hose fitting 11 Shut-off valve (oil drain)
7 Shut-off valve

Changing the oil with internal pressure Changing the oil using an external compressed
air source
The machine has been running for at least 5 mi‐ The supply disconnecting device is switched off,
nutes under LOAD. the device is locked off,
The machine is fully vented, the pressure gauge a check has been made that no voltage is present.
on the oil separator tank reads 0 bar. The machine is fully vented, the pressure gauge
1. Close the shut-off valve 10 in the venting on the oil separator tank reads 0 bar.
line. An external source of compressed air is available.
2. Start the machine and watch the oil separator 1. Close the shut-off valve 10 in the venting
tank pressure gauge 2 until it reads 3–5 bar. line.
3. Switch off and lock out the power supply dis‐ 2. With the shut-off valve closed, insert the male
connecting device and check that no voltage hose fitting 6 into the hose coupling 3 .
is present. 3. Connect the maintenance hose to the exter‐
4. Wait at least 2 minutes to allow the oil to flow nal air supply.
back to the separator tank. 4. Open the shut-off valve 7 until the pressure
gauge on the oil separator tank reads 3–5 bar.
5. Close the shut-off valve 7 and remove the
male hose fitting from the coupling.

Draining the oil from the separator tank

1. Have an oil receptacle ready.

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10.16 Changing the cooling oil

2. With the shut-off valve 7 closed, insert the male hose fitting 6 into the hose coupling 9 .
3. Place the end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valve 11 .
5. Slowly open the shut off valve 7 in the maintenance hose to release oil and close immediately
when air escapes.
6. Close the shut-off valve 11 and unplug the male hose fitting.

Draining the oil from the cooler

Fig. 32 Changing the cooling oil, oil cooler

1 Oil cooler 6 Male hose fitting
2 Hose coupling (oil drainage) 7 Shut-off valve
3 Shut-off valve

1. Have an oil receptacle ready.

2. With the shut-off valve 7 closed, insert the male hose fitting 6 into the hose coupling 2 .
3. Place the end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valve 3 .
5. Slowly open the shut-off valve 7 and allow cooling oil and air to escape completely until the
pressure gauge reads 0 bar.
6. Close the shut-off valve 3 and unplug the male hose fitting.

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10.16 Changing the cooling oil

Draining the oil from the airend

Fig. 33 Changing the cooling oil, airend

1 Compressed air outlet on airend 4 Safety screen
2 Hose coupling (oil drainage) 5 Coupling
3 Shut-off valve

1. Have an oil receptacle ready.

2. With the shut-off valve closed 7 , insert the male hose fitting 6 (Fig. 31) into the hose cou‐
pling 2 .
3. Place the end of the maintenance hose in the oil receptacle and secure it in place.
4. Open shut-off valves 3 and 7 (Fig. 31)
5. Remove the coupling safety screen 4 and turn the coupling 5 by hand at least five revolutions
until all the oil has run out.
6. Fit the safety screen again.
7. Close the shut-off valve 3 and unplug the male hose fitting.

Result The cooling oil is drained from the airend.

A small amount of cooling oil may flow back into the oil cooler and oil separator tank as a result of
turning the coupling.
Remove this by repeating the steps for draining oil from the separator tank and oil cooler.

Option W1–W3 Draining the oil from the heat recovery system

Shut-off valves are provided for draining the oil from the heat recovery system. In machines equipped
with an external heat recovery system (option W1), the oil is drained from the appropriate point.

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10.17 Changing the Oil Filter

Fig. 34 Changing the cooling oil, heat recovery system

1 Hose coupling
2 Thermostatic valve
3 Shut-off valve

1. Have an oil receptacle ready.

2. Insert the male hose fitting 6 (Fig. 31) in the hose coupling 1 .
3. Place the end of the maintenance hose in the oil receptacle and secure it in place.
4. Open the shut-off valves 3 and 7 (Fig. 31) and allow the oil to drain completely.
5. Close the shut-off valve 3 and unplug the male hose fitting.

Filling with oil

1. Open the filler plug 4 (Fig. 31) slowly.

2. Fill with cooling oil.
3. Check the filler plug and ring seal for damage and screw the plug back in again.

Starting the machine and carrying out a trial run

1. Close all access doors, replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air network.
3. Switch on the power supply and reset the maintenance interval counter.
4. Start the machine and check the oil level again after about 10 minutes, topping up if necessary.
5. Switch off the machine and check visually for leaks.
➤ Dispose of used oil in accordance with environmental protection regulations.

10.17 Changing the Oil Filter

The machine must be isolated from the air system and completely vented before undertaking
any work on the pressure system.

Material Replacement part

Cooling oil container

Precondition The power supply disconnecting (isolating) device is switched off,

the disconnect device is locked in the off position,
a check has been made that no voltage is present.
The machine is fully vented, the pressure gauge on the oil separator cartridge reads 0 bar.

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10.18 Changing the oil separator cartridge

WARNING
There is risk of burns from hot components and oil.
➤ Wear long-sleeved clothing and gloves.

Fig. 35 Changing the oil filter

1 Oil filter
2 Direction to unscrew

Changing the oil filter

1. Unscrew the oil filter anti-clockwise, catch oil spillage and dispose of in accordance with envi‐
ronmental protection regulations.
2. Lightly oil the new filter's O-ring.
3. Turn the oil filter clockwise by hand to tighten.
➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.

Starting the machine and carrying out a test run

1. Close all access doors; replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the air system.
3. Switch on the power supply and reset the maintenance interval counter.
4. After about 10 minutes, check the oil level again and top up if necessary.
5. Switch off the machine and visually check for leaks.

10.18 Changing the oil separator cartridge

The machine must be isolated from the compressed air network and completely vented before
undertaking any work on the pressure system.
The oil separator cartridge cannot be cleaned.

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10.18 Changing the oil separator cartridge

The life of the oil separator cartridge is influenced by:

■ contamination in the air drawn into the compressor,
■ Adherence to the changing intervals for:
─ Cooling oil
─ Oil filter
─ Air filter

Material Spares
Cleaning cloths

Precondition The supply disconnecting device is switched off,

the device is locked off,
a check has been made that no voltage is present.
The machine is fully vented, the pressure gauge on the oil separator tank reads 0 bar.

Fig. 36 Changing the oil separator cartridge

1 Fitting 5 Fixing screws
2 Dirt trap 6 Gasket
3 Fitting 7 Oil separator cartridge
4 Air pipe 8 Cover

Changing the oil separator cartridge

1. Unscrew the fitting 1 and carefully put the parts to one side, then pull out the copper pipe from
the dirt trap 2 .
2. Loosen the fitting 3 and disconnect the air pipe 4 completely if necessary.
3. Remove the cover fixing screws 5 and carefully remove the cover 8 .
4. Take out the old oil separator cartridge 7 together with the gaskets 6 and dispose of according
to environmental protection regulations.
5. Clean all sealing faces.
6. Insert the new oil separator cartridge with gaskets and screw down the cover 8 .
7. Renew the O-ring and strainer in the dirt trap 2 .

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10.19 Assembling flexible pipe connections

8. Secure the air pipe 4 with a new self-locking nut.

See chapter10.19 "Assembly of flexible pipe connections"

9. Replace and tighten all fittings.

➤ Dispose of parts and materials contaminated with oil in accordance with environmental
protection regulations.

Starting the machine and carrying out a trial run

1. Close all access doors, replace and secure all removable panels.
2. Open the user's shut-off valve between the machine and the compressed air network.
3. Switch on the power supply and reset the maintenance interval counter.
4. Stop the machine after 10 minutes and visually check for leaks.

10.19 Assembling flexible pipe connections

With the machine depressurized, the clamping bolts must be freely movable by hand and par‐
allel with the pipe.
All clamping bolts must be equally loaded.
Replace the self-locking nuts.

Fig. 37 Assembling flexible pipe connections

1 Pipe 6 Self-locking nut
2 Seal holder 7 Pipe clamp halves
3 Gasket 8 Self-locking nut
4 Bush d Pipe diameter (outside)
5 Clamping bolts s Dimension of the flexible pipe joint under ten‐
sion.

Precondition The pipe 1 must be deburred and the sealing face clean and undamaged.

1. Slide the seal holder 2 and gasket 3 over the pipe 1 .

2. Slide the pipe end 1 into the bush 4 without pretension.
3. Slide the gasket 3 with seal holder 2 up the sealing face of the bush 4 taking care of pipe
alignment.

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10.19 Assembling flexible pipe connections

4. Tighten up the clamping bolts 5 with the self-locking nuts 6 .

5. Lay the pipe clamp halves 7 over the seal holder 2 and bush 4 and tighten the self-locking
nuts 8 until the dimension s is reached.

Pipe diameter d [mm] Clamp diameter s [mm]

76.0 131.0 ± 2%
28.0 63.0 ± 2%

Tab. 58 Dimensions of the flexible pipe connection

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10.20 Document maintenance and service work.

10.20 Document maintenance and service work.

Machine number:
➤ Enter maintenance and service work carried out in the list.

Date Maintenance task carried out Operating hours Signature

Tab. 59 Logged maintenance tasks

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11.1 Note the Nameplate

11 Spares, Operating Materials, Service

11.1 Note the Nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every enquiry and order for spares.

11.2 Ordering consumable parts and operating materials

KAESER consumable parts and operating materials are all genuine KAESER parts. They are selected
for use in KAESER machines.

WARNING
There is risk of personal injury or damage to the machine resulting from the use of unsuitable spare
parts or operating materials.
Unsuitable or poor quality consumable parts and operating materials may damage the machine or
impair its proper function.
In the event of damage, personal injury may result.
➤ Use only genuine KAESER parts and operating materials.
➤ Have an authorized KAESER Service Technician carry out regular maintenance.

Machine

Name Quantity Number

Air filter element 1 1250
Filter mat (cooler) 4 1050
Filter mat (control cabinet) 2 1100
Oil filter 1 1200
Oil separator cartridge 1 1450
Cooling oil 1 1600
Bearing grease [g] 100 9.0915.0
400 6.3234.0

Tab. 60 Consumable parts

11.3 SIGMA AIR SERVICE

SIGMA AIR SERVICE offers:
■ authorised service technicians with KAESER factory training,
■ increased operational reliability ensured by preventive maintenance,
■ energy savings achieved by avoidance of pressure losses,
■ optimum conditions for operation of the compressed air system,

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11.4 Service Addresses

■ the security of genuine KAESER spare parts,

■ increased legal certainty as all regulations are kept to.

➤ Why not sign a SIGMA AIR SERVICE maintenance agreement!

Result Your advantage:

lower costs and higher compressed air availability.

11.4 Service Addresses

Addresses of KAESER agents are given at the end of this manual.

11.5 Spare parts for service and repair

With the help of this parts list you can plan your material requirement according to operating conditions
and order the spare parts you need.
➤ Make sure that any service or repair tasks not described in this manual are carried out by
an authorized KAESER Service Technician.

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11.5 Spare parts for service and repair

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11.5 Spare parts for service and repair

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11.5 Spare parts for service and repair

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11.5 Spare parts for service and repair

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 12 Decommissioning, Storage and Transport
12.1 Putting Out of Operation

12 Decommissioning, Storage and Transport

12.1 Putting Out of Operation
This is necessary under the following circumstances:
■ The machine is temporarily not needed.
■ The machine is to be moved to another location.
■ The machine is to be scrapped.

Temporarily putting out of operation

Precondition The machine can be started at regular intervals.

➤ Run the machine once a week for at least 30 minutes under LOAD to ensure sufficient protection
against corrosion.

Putting out of operation for a longer period

Precondition Before putting out of operation, the machine should be run under LOAD for at least 30 minutes.
Switch off the mains disconnecting device,
the disconnect device is locked in the off position,
check that no voltage is present.
Machine fully vented (no pressure).

1. Allow the machine to cool down completely.

2. Disconnect all air and electrical connections.

12.2 Packing
A wooden crate is required for overland transport to protect the machine from mechanical damage.
Consult an authorized KAESER Service agent for advice on packing for sea or air transport.

Material Desiccant
Plastic sheeting
Wooden transport crate

Precondition The machine is decommissioned.

Machine is dry and cooled down.

1. Place sufficient desiccant (silica gel or similar) inside the machine cabinet.
2. Wrap the machine in plastic sheeting.

12.3 Storage
Moisture can lead to corrosion, particularly on the surfaces of the airend and in the oil separator tank.
Frozen moisture can damage components, diaphragms, valves and gaskets.
Advice can be obtained from KAESER on storage and commissioning.

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12.4 Transporting

CAUTION
Moisture and frost can damage the machine.
➤ Prevent ingress of moisture and formation of condensation.
➤ Maintain a storage temperature of >0 °C.

➤ Store the machine in a dry, frost-proof room.

12.4 Transporting
12.4.1 Safety
Weight and centre of gravity determine the most suitable method of transport. The centre of gravity
is shown in the drawing in chapter 13.3.

Precondition Transport only by fork truck or lifting gear with personnel trained in the safe transport of goods.

➤ Make sure the danger zone is clear.

12.4.2 Transporting with a forklift truck

Precondition The forks are fully under the machine.

Fig. 38 Transporting with a forklift truck

➤ Drive the forks completely under the machine or palette and lift carefully.

12.4.3 Transporting with a crane

Suitable lifting gear ensures correct transportation.
The lifting slings must be fully under the machine.
The slings may not bear on the side of the machine cabinet.

Examples of unsuitable fixing points:

■ Pipe sockets
■ Flanges
■ Attached components such as cyclone separators, condensate drains or filters
■ Rain protection covers

Precondition The lifting gear complies with local safety regulations.

No pressure should bear on the sides of the machine cabinet.

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12.5 Disposal

Fig. 39 Transporting with a crane

1 Lifting gear
2 Slings

CAUTION
The machine can be damaged by incorrect attachment of the lifting gear.
➤ Do not attach the lifting gear to any of the machine components.
➤ The manufacturer can advise on the use of suitable lifting gear.

➤ Use the lifting gear correctly and lift the machine carefully.

12.5 Disposal
When disposing of a machine, drain out all liquids and remove dirty filters.

Precondition The machine is decommissioned.

1. Completely drain the cooling oil from the machine.

2. Remove used filters and the oil separator cartridge.
3. Hand the machine over to an authorized disposal expert.
➤ Components contaminated with cooling oil must be disposed of in accordance with local
environment protection regulations.

Machines with refrigeration dryers

The sealed refrigerant circuit still contains both refrigerant and oil.
➤ Refrigerant and oil must be drained and disposed of by an authorized body.

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13.1 Pipeline and instrument flow diagram (P+I diagram)

13 Annex
13.1 Pipeline and instrument flow diagram (P+I diagram)

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13.1 Pipeline and instrument flow diagram (P+I diagram)

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13.1 Pipeline and instrument flow diagram (P+I diagram)

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13.1 Pipeline and instrument flow diagram (P+I diagram)

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13.1 Pipeline and instrument flow diagram (P+I diagram)

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13.1 Pipeline and instrument flow diagram (P+I diagram)

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13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode

13.2 Option C1
Pipe and Instrument Flow Diagram (P+I diagram): MODULATING
control mode

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13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode

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13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode

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13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode

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13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode

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13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode

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13.3 Dimensional Drawing

13.3 Dimensional Drawing

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13.3 Dimensional Drawing

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13.3 Dimensional Drawing

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13.3 Dimensional Drawing

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13.4 Electrical Diagram

13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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13.4 Electrical Diagram

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 Bedienungsanleitung
Instruction Manual

Adsorptionstrockner / Desiccant Compressed Air Dryer

Modell / Model

DC-12E, DC-18E, DC-27E, DC-33E, DC-50E,

DC-75E, DC-108E, DC-133E

Kaeser Kompressoren GmbH

Postfach 2143
96410 Coburg
Tel.: 09561/640-0
Fax: 09561/640130
http://www.kaeser.com

gültig ab 01.04.2007 A3237 07.03.07 SK 07.03.07 KC A2826

- 1 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

DC12E-DC133E 08 D E
Materialkennzeichnung Sign of material

Adsorptionstrockner / Nr. / No.

Desiccant dryer
DC-12E 9.5481.00010
DC-18E 9.5482.00010
DC-27E 9.5483.00010
DC-33E 9.5484.00010
DC-50E 9.5485.00010
DC-75E 9.5486.00010
DC-108E 9.5487.00010
DC-133E 9.5488.00010

A3237 07.03.07 SK 07.03.07 KC A2826

- 2 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

 Inhaltsverzeichnis Contents

Seite Page

Allgemein General
1. Einleitung 1. Introduction
1.1 Allgemeines ........................................... 8 1.1 General remarks .................................... 8
1.2 Erklärung der Symbole 1.2 Explanation of the symbols in the
in der Bedienungsanleitung ................ 8 operating instructions ........................... 8
1.3 Erklärung der Symbole 1.3 Symbols used in the dryer ................... 8
am Gerät ................................................ 8

2. Sicherheitsregeln, Warnhinweise 2. Safety rules, warnings

2.1 Bestimmungsgemäßer Gebrauch ........ 9 2.1 Use of the dryer ..................................... 9
2.2 Sicherheitsregeln .................................. 9 2.2 Safety rules ............................................ 9
2.3 Warnhinweise ........................................ 10 2.3 Security-Warnings ................................. 10

3. Garantiebedingungen 3. Guarantee conditions

3.1 Allgemeines ........................................... 11 3.1 General .................................................. 11
3.2 Garantieausschluß ................................ 11 3.2 Exclusion from guarantee coverage ... 11

Anleitung für den Bediener Instructions for the user

4. Betrieb (Einschalten, Ausschalten, 4. Operation (switching on, switching off,
Bedienungselemente) controls)
4.1 Betriebsbereitschaft .............................. 12 4.1 Preconditions for operation ................. 12
4.2 Einschalten ............................................ 12 4.2 Switching on the dryer ......................... 12
4.3 Betrieb .................................................... 13 4.3 Operation ............................................... 13
4.4 Ausschalten ............................................ 13 4.4 Switching off the dryer ......................... 13
4.5 Bedienungselemente ............................ 14 4.5 Controls .................................................. 14

5. Störungen, Störungsbeseitigung 5. Malfunctions, troubleshooting

5.1 Störungen ohne Störmeldung ............. 15 5.1 Malfuntions without fault messages .... 15
5.2 Störungen mit Störmeldung ................. 16 5.2 Malfunctions with fault messages ........ 16

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Anleitung für Wartungs-, Instructions for service- and

Instandhaltungspersonal maintenance staff
6. Transport, Anlieferung, 6. Transportation, delivery, inspection of
Wareneingangskontrolle incoming goods
6.1 Transport ................................................ 17 6.1 Transport ................................................ 17
6.2 Anlieferung ............................................ 17 6.2 Delivery .................................................. 17
6.3 Wareneingangskontrolle ...................... 17 6.3 Checking at receipt ............................... 17

7. Aufstellung, Montage 7. Installation, assembly

7.1 Aufstellungsort ....................................... 18 7.1 Location of installation ......................... 18
7.2 Montage ................................................. 18 7.2 Mounting ................................................ 18
7.3 Anschluß an das Druckluftnetz ............ 18 7.3 Connection to the compressed air
7.4 Vor- und Nachfilter ................................ 18 system .................................................... 18
7.5 Kondensatableitung .............................. 18 7.4 Pre- and after filter................................ 18
7.6 Elektroanschluß ..................................... 19 7.5 Condensate drain .................................. 18
7.6 Electrical connection ............................ 19

8. Erste Inbetriebnahme 8. Initial Start-up

Inbetriebnahme nach längerem Stillstand Start-up after prolonged inoperative
8.1 Bedingungen ......................................... 20 periods
8.2 Einschalten ............................................ 20 8.1 Preconditions ......................................... 20
8.3 Einstellen des Druckes vor der 8.2 Switching on the dryer ......................... 20
Regenerationsluftblende ...................... 21 8.3 Adjust the pressure at purge air
8.4 Austausch der orifice ..................................................... 21
Regenerationsluftblende ...................... 22 8.4 Exchange of the orifice ........................ 22
8.5 Drucktaupunkt wählen .......................... 22 8.5 Select the pressure dewpoint .............. 22

9. Steuerung (ECO CONTROL) 9. Control (ECO CONTROL)

9.1 Anschlüsse-Eco Control ........................ 23 9.1 Connections-Eco Control ...................... 23
9.1.1 Anschlüsse-Sammelstörmeldung ...... 23 9.1.1 Connections-Common alarm
9.1.2 Alarme ................................................. 23 contacts ............................................... 23
9.1.3 Anschlüsse-Fern Ein/Aus ................... 24 9.1.2 Common alarm relay logic ............... 23
9.1.4 Anschlüsse-Alarm hoher Taupunkt ... 25 9.1.3 Connections-Remote on/off ............... 24
9.2 Jumper auf der Steuerplatine .............. 25 9.1.4 Connections-High humidity or
9.3 Bedienelemente .................................... 26 dewpoint alarm .................................. 25
9.3.1 EIN/AUS-Schalter ................................ 26 9.2 Control Board Jumpers ......................... 25
9.4 Ereignisabfolge und 9.3 Controls .................................................. 26
Komponentenstatus .............................. 26 9.3.1 Dryer On/Off Switch ........................... 26
9.5 Programmmodus ................................... 26 9.4 Front Panel Operation .......................... 26
9.5.1 Screen 1-Anwahl der Sprache .......... 27 9.5 Program Mode ....................................... 26
9.5.2 Screen 2-Auto Neustartmodus ........... 27 9.5.1 Screen 1-Select the language .......... 27
9.5.3 Screen 3-Alarmpunkt für 9.5.2 Screen 2-Auto restart mode .............. 27
Taupunktsensoreinstellen ................. 27 9.5.3 Screen 3-Alarm point for dew
9.5.4 Screen 4-Serviceebene ..................... 28 point sensor ........................................ 27
9.5.5 Screen 5-Rücksetzung des 9.5.4 Screen 4-Service level ...................... 28
Timers für Filterservice ..................... 28 9.5.5 Screen 5-Reset the timer for
9.5.6 Screen 6-Rücksetzung des filter service ........................................ 28
Timers für Trockenmittelservice ....... 28 9.5.6 Screen 6-Reset the timer for
desiccant service ............................... 28

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9.5.7 Screen 7-Rücksetzung des Timers 9.5.7 Screen 7-Reset the timer for
für Ventilservice .................................. 29 valve service ........................................ 29
9.5.8 Screen 8-Rücksetzung des Zählers 9.5.8 Screen 8-Reset the valve cycle
für den Ventilzyklus............................. 29 counter ................................................. 29
9.6 Setup-Modus ............................................ 29 9.6 Setup Mode .............................................. 29
9.6.1 Screen 1-Anwahl der 9.6.1 Screen 1-Select the dew point class .. 30
Taupunktklasse .................................... 30 9.6.2 Screen 2-Select the cycle type ........... 30
9.6.2 Screen 2-Anwahl des Zyklustyps ......... 30 9.6.3 Screen 3-Test the drains ...................... 30
9.6.3 Screen 3-Kondensatableitertest .......... 30 9.7 Alarm & Service Mode ............................ 30
9.7 Alarm- und Servicemodus ...................... 30 9.7.1 Alarm messages ................................... 31
9.7.1 Störungen ............................................. 31 9.7.1.1 Pressure Switch Alarms .................... 31
9.7.1.1 Druckschalteralarme ......................... 31 9.7.1.2 Thermistor Alarms ............................. 31
9.7.1.2 Thermosensor-Störungen ................. 31 9.7.1.3 Optional Device Alarms .................... 31-32
9.7.1.3 Optionale Vorrichtung Alarme ......... 31-32 9.7.1.4 Alarm Mode Screen 1-Left tower
9.7.1.4 Alarmmodus Screen 1-Linker drying -low pressure ......................... 32
Behälter trocknet-Niedrigdruck ....... 32 9.7.1.5 Alarm Mode Screen 2-Left tower
9.7.1.5 Alarmmodus Screen 2-Linker regenerating-high pressure ............. 32
Behälter regeneriert-Hochdruck ...... 32 9.7.1.6 Alarm Mode Screen 3-Left tower
9.7.1.6 Alarmmodus Screen 3-Linker regenerating-low pressure ............... 32
Behälter regeneriert-Niedrigdruck .. 32 9.7.1.7 Alarm Mode Screen 4-Left tower
9.7.1.7 Alarmmodus Screen 4-Linker Mode Screen 4-Left tower, upper
Behälter, oberer Sensor Wert sensor (Thermistor) under range ..... 32
unterhalb des Meßbereiches ........... 32 9.7.1.8 Alarm Mode Screen 5 – Left Tower,
9.7.1.8 Alarmmodus Screen 5–Linker Upper Sensor (Thermistor)
Behälter, oberer Sensor Wert Over-Range ........................................ 33
oberhalb des Meßbereiches ............ 33 9.7.1.9 Alarm Mode Screen 6 – Left Tower,
9.7.1.9 Alarmmodus Screen 6–Linker Lower Sensor (Thermistor)
Behälter, unterer Sensor Wert Under-Range ..................................... 33
unterhalb des Meßbereiches ........... 33 9.7.1.10 Alarm Mode Screen 7 – Left Tower,
9.7.1.10 Alarmmodus Screen 7–Linker Lower Sensor (Thermistor)
Behälter, unterer Sensor Wert Over-Range ..................................... 33
oberhalb des Meßbereiches .......... 33 9.7.1.11 Alarm Mode Screen 8 - Right Tower
9.7.1.11 Alarmmodus Screen 8-Rechter Drying – Low Pressure (Open
Behälter trocknet-Niedrigdruck Pressure Switch Circuit) ................... 33
(offener Druckschalterkontakt) ........ 33 9.7.1.12 Alarm Mode Screen 9 – Right
9.7.1.12 Alarmmodus Screen 9–Rechter Tower Regenerating – High Pressure
Behälter regeneriert-Hochdruck(ge- (Closed Pressure Switch Circuit .......... 33
schlossener Druckschalterkontakt) .... 33 9.7.1.13 Alarm Mode Screen 10 – Right
9.7.1.13 Alarmmodus Screen 10–Rechter Tower Regenerating- Low Pressure
Behälter regeneriert - Niedrigdruck (Open Pressure Switch Circuit) .......... 33
(offener Druckschalterkontakt) ....... 33 9.7.1.14 Alarm Mode Screen 11–Right Tower,
9.7.1.14 Alarmmodus Screen 11–Rechter Upper Sensor (Thermistor)
Behälter, oberer Sensor Wert unterhalb Under-Range .................................... 34
des Meßbereiches ............................. 34 9.7.1.15 Alarm Mode Screen 12–Right Tower,
9.7.1.15 Alarmmodus Screen 12–Rechter Upper Sensor (Thermistor)
Behälter, oberer Sensor Wert oberhalb Over-Range ....................................... 34
des Meßbereiches ............................. 34 9.7.1.16 Alarm Mode Screen 13–Right Tower,
9.7.1.16 Alarmmodus Screen 13–Rechter Lower Sensor (Thermistor)
Behälter, unterer Sensor Wert Under-Range .................................... 34
unterhalb des Meßbereiches ............. 34 9.7.1.17 Alarm Mode Screen 14–Right Tower,
9.7.1.17 Alarmmodus Screen 14–Rechter Lower Sensor (Thermistor)
Behälter, unterer Sensor Wert Over-Range ....................................... 34
oberhalb des Meßbereiches .............. 34 9.7.1.18 Alarm Mode Screen 15 –
9.7.1.18 Alarmmodus Screen 15– Alarm Drain 1 ................................... 34
Alarm Kondensatableiter 1 ............ 34 9.7.1.19 Alarm Mode Screen 16 –
9.7.1.19 Alarmmodus Screen 16 – Alarm Drain 2 ................................... 34
Alarm Kondensatableiter 2 ........... 34
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9.7.1.20 Alarmmodus Screen 17 – Alarm .... 35 9.7.1.20 Alarm Mode Screen 17 – Alarm ..... 35
9.7.1.21 Alarmmodus Screen 18 – Alarm .... 35 9.7.1.21 Alarm Mode Screen 18 – Alarm ..... 35
9.7.2 Servicemeldungen ............................... 35 9.7.2 Service messages ................................ 35
9.7.2.1 Servicemodus Screen 1-Service 9.7.2.1 Service Mode Screen 1-Servce
Filter .................................................. 35 filters ................................................... 35
9.7.2.2 Servicemodus Screen 2 – 9.7.2.2 Service Mode Screen 2 –
Service Trockenmittel ...................... 36 Service desiccant ............................. 36
9.7.2.3 Servicemodus Screen 3 – 9.7.2.3 Service Mode Screen 3 –
Service Ventile ................................. 36 Service valves ................................... 36
9.8 Displaymodus .......................................... 36 9.8 Display Mode ........................................... 36
9.8.1 Displaymodus Screen 1 – 9.8.1 Display Mode Screen 1 –
Taupunktklasse und Zyklustyp ........... 36 Dew point class and cycle type. ........ 36
9.8.2 Displaymodus Screen 2 – 9.8.2 Display Mode Screen 2 –
Energiesparen ..................................... 36 Energy savings. ................................... 36
9.8.3 Displaymodus Screen 3A – 9.8.3 Display Mode Screen 3A –
Serviceerinnerung (Filter) .................. 37 Service reminder (filters) ................... 37
9.8.4 Displaymodus Screen 3B – 9.8.4 Display Mode Screen 3B –
Serviceerinnerung (Trockenmittel) .... 37 Service reminder (desiccant) ............. 37
9.8.5 Displaymodus Screen 3C – 9.8.5 Display Mode Screen 3C –
Serviceerinnerung (Ventile) ............... 37 Service reminder (valves) .................. 37
9.8.6 Displaymodus Screen 3D – 9.8.6 Display Mode Screen 3D –
Zähler Ventilzyklus .............................. 37 Valve cycle counter ............................. 37
9.8.7 Displaymodus Screen 4–Taupunkt 9.8.7 Display Mode Screen 4 – Dryer
Trocknerausgang (AUX2, outlet dew point,(AUX2, analog
Analogeingang .................................... 37 input) .................................................... 37
9.8.8 Displaymodus Screen 5 – 9.8.8 Display Mode Screen 5 – Dryer inlet
Eintrittsdruck Trockner (AUX3, pressure, (AUX3, analog input) .......... 37
Analogeingang) ................................... 37 9.8.9 Display Mode Screen 6 – Dryer inlet
9.8.9 Displaymodus Screen 6 – temperature, (AUX3, analog input) .... 37
Eintrittstemperatur Trockner (AUX3, 9.9 Test Mode ................................................. 38-39
Analogeingang) ................................... 37 9.9.1 Test Mode Screen 1 – Step 1 ............... 40
9.9 Testmodus ................................................ 38-39 9.9.2 Test Mode Screen 2 – Step 2 ............... 40
9.9.1 Testmodus Screen 1 – Schritt 1 ........... 40 9.9.3 Test Mode Screen 3 – Step 3 ............... 40
9.9.2 Testmodus Screen 2 – Schritt 2 ........... 40 9.9.4 Test Mode Screen 4 – Step 4 ............... 40
9.9.3 Testmodus Screen 3 – Schritt 3 ........... 40 9.9.5 Test Mode Screen 5 – Step 5 ............... 40
9.9.4 Testmodus Screen 4 – Schritt 4 ........... 40 9.9.6 Test Mode Screen 6 – Step 6 ............... 41
9.9.5 Testmodus Screen 5 – Schritt 5 ........... 40 9.9.7 Test Mode Screen 7 – Step 7 ............... 41
9.9.6 Testmodus Screen 6 – Schritt 6 ........... 41 9.9.8 Test Mode Screen 8 – Step 8 .............. 41
9.9.7 Testmodus Screen 7 – Schritt 7 ........... 41 9.9.9 Test Mode Screen 9 – Attempting to
9.9.8 Testmodus Screen 8 – Schritt 8 ........... 41 exit test mode from step 2, 3, or 4 ..... 41
9.9.9 Testmodus Screen 9 – Test modus
verlassen aus Schritt 2, 3 oder 4 ....... 41

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9.9.10 Testmodus Screen 10 – Test modus 9.9.10 Test Mode Screen 10 – Attempting to
verlassen aus Schritt 6, 7 oder 8 ...... 41 exit test mode from step 6,7, or 8 ... 41
9.10 Zeiten der festen Zykluszeiten ............. 42 9.10 Fixed Cycle timing ................................ 42
9.11 Zeitlicher Ablauf des Bauteilestatus .... 43 9.11 Event Sequence and Component
9.12 Panel Layout .......................................... 44 Status .................................................... 43
9.13 Programmschritte im manuellen 9.12 Panel Layouts ........................................ 44
Bereich .................................................. 45 9.13 Steps in the manual mode ................... 45

10. Funktionsbeschreibung 10. Description of operation

10.1 Wirkungsweise .................................. 46-47 10.1 Operation ........................................... 46-47
10.2 ECO-Control ....................................... 47 10.2 ECO-Control ....................................... 47

11. Wartung, Instandhaltung 11. Servicing, maintenance

11.1 Wöchtliche Wartungsarbeiten ............ 48 11.1 Weekly maintenance ........................ 48
11.2 Jährliche Wartungsarbeiten ............... 49 11.2 Annual maintenance ......................... 49
11.3 Entlüftung des Adsorptionstrockners . 49 11.3 Unpressurize the desiccant dryer ..... 49
11.4 Austausch von Trockenmittel .............. 50 11.4 Replacement of desiccant ................ 50
11.5 Wartungspakete ................................... 51 11.5 Maintenance packages ..................... 51

12. Technische Daten ..................................... 52-55 12. Technical data .......................................... 52-55

13. R&I-Schema (Fließbild), Stückliste ......... 56-57 13. P&I- Diagram (flow diagram), parts list ... 56-57

14. Schaltplan, Stückliste .............................. 58-59 14. Wiring diagram, parts list ........................ 58-59

15. Maßzeichnung ......................................... 60-67 15. Dimensional drawing ............................... 60-67

Wir haben den Inhalt der Bedienungsanleitung auf Übereinstim- We have examined the content of the operating instructions for
mung mit dem beschriebenen Gerät geprüft. conformity with the appliance described.
Dennoch können Abweichungen nicht ausgeschlossen werden, Inconsistencies cannot be ruled out, however, with the result
so daß wir für die vollständige Übereinstimmung keine Gewähr that we do not guarantee complete conformity
übernehmen.
We reserve the right to alter the specifications without prior
Technische Änderungen vorbehalten. notice

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 1. Einleitung 1. Introduction

1.1 Allgemeines 1.1 General remarks

Der in dieser Betriebsanleitung dokumentierte Adsorptions- The desiccant compressed air dryer documented in these
trockner erfüllt alle Anforderungen, die an ein modernes Gerät operating instructions has all requirements that can be expected
gestellt werden. from a modern device.
Um ihn optimal nutzen zu können, benötigt der Anwender aus- In order to obtain maximum benefit from using this dryer the user
führliche Informationen. should have sufficient information to ensure the unit is installed
and operated correctly, enabling the user to avoid accidents and
In der vorliegenden Betriebsanleitung haben wir diese Informa- retain the manufacturers warranty.
tionen vollständig und in entsprechende Kapitel gegliedert zu-
sammengestellt. These operating instructions will give the user this information.
For ease of references tha manual has been divided into separa-
Lesen Sie die Bedienungsanleitung vor Inbetriebnahme te sections.
der Maschine durch,
um eine von Anfang an sachgemäße Handhabung, Bedienung Read the operating instructions, prior to starting the
und Wartung zu gewährleisten. machine,
Im Wartungsplan sind alle Maßnahmen zusammengestellt, die den in order to ensure correct handling, operation and maintenance
Trockner in gutem Zustand erhalten. Die Wartung ist einfach, from the outset.
muß jedoch regelmäßig vorgenommen werden. The maintenance plan summarizes all the measures which are
Sie hilft Ihnen auch Unfälle zu vermeiden und die Garantie des required to maintain the dryer in good condition. The maintenance
Herstellers zu erhalten. work is simple, but must be carried out on a regular basis.
Correct maintenance will also help you to avoid accidents and to
Nennen Sie bei jedem Schriftverkehr immer den Typ und die voll- ensure that the manufacturer`s guarantee coverage is maintained.
ständige Seriennummer des Trockners, die auf dem Typenschild
angegeben sind. Please state the type and complete serial number of the dryer, as
specified on the nameplate, in all correspondence.

1.2 Erklärung der Symbole in der 1.2 Explanation of the symbols in the
Bedienungsanleitung operating instructions
Alle Sicherheitshinweise in dieser Bedienungsanleitung, die bei All safety instructions in this operating manual, failure to observe
Mißachtung Personen- bzw. Sachschäden zur Folge haben kön- which may result in damage or injury, are classified by the symbols
nen, sind durch die nachstehenden Symbole gekennzeichnet. below.

Allgemeines Gefahrensymbol General danger symbol

Elektrisches Gefahrensymbol Electrical danger symbol

Netzstecker ziehen Disconnect mains plug

1.3 Erklärung der Symbole am Gerät 1.3 Symbols used in the dryer

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 2. Sicherheitsregeln, 2. Safety rules,
Warnhinweise warnings

2.1 Bestimmungsgemäßer Gebrauch 2.1 Use of dryer

Achtung! Attention !
• Das Gerät/System darf nur für die in dieser Betriebsan- • The dryer/system must only be used for the purpose as
leitung vorgesehenen Einsatzfälle und nur in Verbindung designated in the operating instructions and only in
mit vom Hersteller empfohlenen bzw. zugelassenen Ge- combination with any device or components
räten und Komponenten verwendet werden. recommended or approved by the manufacturer.

• Die maximale Eintrittskonzentration der Druckluft muß den • The max. inlet concentration should be according to DIN
nachfolgend aufgeführten Klassen der DIN ISO 8573-1 ISO 8573-1
entsprechen Moisture: Class 7
Feuchtigkeit: Klasse 7 Particle: 1) Class 7
Feststoffe 1): Klasse 7 Oil content: Class 1 (reaches by series FE)
Ölgehalt: Klasse 1 (durch Serie FE erreicht)

• Der einwandfreie und sichere Betrieb des Produktes er- • To obtain maximum efficiency and operation of the dryer
fordert sachgerechten Transport, Lagerung, Aufstellung ensure all sections of the manual are read carefully.
und Montage, sowie sorgfältige Bedienung und Instand-
haltung.
• This product is not designed for earthquake endangered
• Das Gerät ist nicht für einen Betrieb in erdbebengefähr- areas!
deten Regionen geeignet!
• The dryer must not operate in corrosive atmospheres!
• Der Trockner darf nicht in korrosiver Atmosphäre
betrieben werden!

1) 1)
Feststoffbeladung nach ISO8573-1: 1991 Particle according to ISO8573-1: 1991

Der Errichter der kompletten Druckluftstation muß The manufacturer of the complete unit has to
das Gerät mit einem geeigneten Sicherheitsventil provide the air dryer with an appropriate safety
(Ps=16bar) gegen Überdruck absichern (siehe R&I- valve (Ps=16bar) in order to protect it against
Schema) overpressure (see P&I-Diagram)

Remark!
Achtung! No aggressive components are allowed (f.ex. acid,
Die Bestandteile der Druckluft dürfen nicht aggres- amonia)
siv oder säurebildend sein (z.B. säurehaltige Dämp-
fe, Ammoniak)!

2.2 Sicherheitsregeln 2.2 Safety rules

Warnung! Warning!
• Das Gerät darf nur von geschultem Personal genutzt, • The dryer must only be used, operated, inspected and
bedient, gewartet und instandgesetzt werden, das hiermit repaired by trained personnel who are familiar with the
vertraut und über die damit verbundenen Gefahren un- unit and possible dangers in unauthorised operation or
terrichtet ist. service.
Geschultes Personal im Sinne der sicherheitsbezogenen Trained personnel are defined as follows:
Hinweise in dieser Dokumentation oder auf dem Produkt
selbst, ist Personal, das: * Operating staff who are skilled in the field of compressed
air engineering and an familiar with the contents of this
* als Bedienungspersonal im Umgang mit Einrichtungen der operation instruction manual.
Drucklufttechnik unterwiesen ist und den auf die Bedie-
nung bezogenen Inhalt dieser Dokumentation kennt; * Maintenance staff who are familiar and aware of the
possible dangers in the fields of compressed air, and
* oder als Inbetriebsetzungs- und Wartungspersonal mit electrical engineering, and who have had the appropriate
den Sicherheitskonzepten der Druckluft- und Elektrotech- training and an qualified as being competent in these
nik vertraut ist. fields.
Es besitzt als solches eine zur Inbetriebnahme und War-
tung derartiger Einrichtungen befähigende Ausbildung
bzw. Berechtigung.

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 2. Sicherheitsregeln, 2. Safety rules,
Warnhinweise warnings

2.3 Warnhinweise 2.3 Security-Warnings

Warnung! Warning!
Das Gerät beinhaltet unter erhöhtem Luftdruck stehende The dryer contains components under high pressure.
Systeme. Before starting any service work turn off compressed air
Vor Servicearbeiten ist es drucklos zu machen. supply to the dryer and depressurise the system.

Vorsicht Lebensgefahr ! Electrical Danger!

Das Gerät enthält unter elektrischer Spannung stehende The dryer contains components that are electrically live
Bauteile. and which can cause danger to life.

Vor Servicearbeiten ist es allpolig vom elektrischen Before starting any service work ensure all power is
Spannungsversorgungsnetz zu trennen. isolated from the dryer, mains plug if fitted to be removed.
(Netzstecker ziehen)
Attention!
ACHTUNG! Any electrical work on the dryer must only be
Alle Arbeiten am elektrischen System dürfen nur carried out by skilled staff - qualified electricians,
von elektrotechnisch geschultem Fachpersonal, or persons under supervision of qualified staff.
oder unter Aufsicht von diesem, durch Unterwie-
sene ausgeführt werden.

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 3. Garantiebedingungen 3. Guarantee conditions

3.1 Allgemeines 3.1 General

Die Garantie erstreckt sich, im Rahmen unserer allgemeinen Lie- The guarantee covers the delivered device with regard to our
ferbedingungen, auf das gelieferte Gerät. general terms of delivery.

3.2 Garantieausschluß 3.2 Exclusion from guarantee coverage

Garantieansprüche bestehen nicht, No guarantee claims shall be assertible,

• wenn das Gerät durch Einfluß höherer Gewalt oder durch • if the device is damaged or destroyed due to force majeurs
Umwelteinflüsse (Feuchtigkeit, Stromschläge, etc.) be- or environmental effects (humidity, electric shocks, etc.).
schädigt oder zerstört wird.
• for damage resulting from incorrect handling, in particular
• bei Schäden, die durch unsachgemäße Behandlung, ins- failure to comply with the operating and maintenance
besondere Nichtbeachtung der Betriebs- und Wartungs- instructions (regular inspection of the condensate
anleitung aufgetreten sind (regelmäßige Kontrolle des discharger, etc.).
Kondensatableiter, etc.).
• if the device has not been used in accordance with its
• falls das Gerät nicht seinen Bestimmungen entsprechend specifications (see Section 12. „Technical Data“).
eingesetzt war (siehe Kapitel 12. "Technische Daten").
• if the device has been opened or repaired by workshops
• falls das Gerät durch nicht hierfür autorisierte Werkstät- or other persons unauthorised for this purpose and/or
ten oder andere Personen unsachgemäß geöffnet oder reveals any type of mechanical damage.
repariert wurde und/oder mechanische Beschädigung
irgendwelcher Art aufweist.

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 4. Betrieb (Einschalten, Ausschalten, 4. Operation (switching on, switching
Bedienungselemente) off, controls)

4.1 Betriebsbereitschaft 4.1 Preconditions for operation

Das Gerät ist betriebsbereit, wenn folgende Bedingun- The dryer is ready for operation when the following condi-
gen erfüllt sind: tions have been fulfilled:“

• Aufstellung des Gerätes gemäß Kapitel 7. „Aufstellung, • Installation of the dryer in accordance with section 7.
und Montage“. „Installation and mounting“.

• Gerät wurde entsprechend Kapitel 8 „Erste Inbetriebnah- • Dryer has been commissioned in accordance with section
me“ in Betrieb genommen. 8. „Initial start-up“.

• Alle Zu- und Ableitungen sind sachgerecht angeschlos- • All inlet and outlet lines have been correctly connected.
sen.
• The required forms of energy (electricity, compressed-
• Die erforderlichen Energien (Elektro; Druckluft) sind ver- air) are available.
fügbar.
• The compressed-air inlet and outlet line is pressurized.
• Die Druckluftein- und -austrittsleitung ist mit Druck beauf-
schlagt. • Shut-off devices in the compressed-air inlet and outlet
lines are open.
• Absperrorgane in der Druckluftein- und austrittsleitung
sind geöffnet. • Bypass (if installed) in the compressed-air line up-line of
the desiccant compressed-air dryer is closed.
• Ein eventuell vorhandener Bypass in der Druckluftleitung
vor dem Adsorptionstrockner ist geschlossen.

4.2 Einschalten 4.2 Switching on the dryer

Gerät nur einschalten, wenn alle Bedingungen des The dryer is to be switched on only when all the re-
Abschnittes4.1 "Betriebsbereitschaft" erfüllt sind. quirements specified in section 4.1 „Preconditions“
have been fulfilled.

Taster „I/0“ betätigen.

Press the „I/0“ button.
• Gerät ist eingeschaltet und in Betrieb.
• The dryer is switched on and operative.

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 4. Betrieb (Einschalten, Ausschalten, 4. Operation (switching on, switching
Bedienungselemente) off, controls)

4.3 Betrieb 4.3 Operation

Die Nummern der Taster und Leuchtdioden sind im The numbers of the buttons and light-emitting
Kapitel 4.5 „Bedienungselemente“ erklärt. diodes are explained in section 4.5 „Controls“.

• Sollte während des Betriebes die Leuchtdiode 19 blin- • Should LED 19 flash at any time after this during operation
ken, liegt eine Störung vor (siehe Kapitel 5. „Störungen“). of the dryer, this indicates a malfunction (see section 5.
„Malfunction“).

Beachten Sie bitte die Hinweise im Kapitel 11.

„Wartung, Instandhaltung“). Please note the information provided in section
11. „Servicing, maintenance".

4.4 Ausschalten 4.4 Switching off the dryer

Achtung! Attention!
Der Adsorptionstrockner darf nur bei gleichem Switch desiccant dryer off just when pressure in
Druck beider Behälter ausgeschaltet werden, da- both towers are the same, so no shock pressure
mit keine Druckstöße im Behälter auftreten. results in vessel.

When the gauges of both towers indicates the same

Wenn die Manometer beider Behälter den gleichen Druck pressure (end of regeneration).
anzeigen (Ende der Regeneration). Press the „I/0“ button.
Taster „I/0“ betätigen.
• Dryer is switched off.
• Gerät ist ausgeschaltet.
• The inlet shut-off devices are open, so that the pressure
• Die Eintrittsarmaturen sind geöffnet, so daß die Druckluft air flows over both towers.
über beide Behälter strömt.

Attention!
Achtung! If the desiccant dryer is switched off, make sure
Bei ausgeschaltetem Adsorptionstrockner darf that no compressed-air being supplied to the
dem Netz keine Druckluft zugeführt werden, um network.
eine Übersättigung des Trockenmittels zu vermei-
den.

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 4. Betrieb (Einschalten, Ausschalten, 4. Operation (switching on, switching
Bedienungselemente) off, controls)

4.5 Bedienungselemente 4.5 Bedienungselemente

1 11
12
2
p1 p2
3 13

p3
4
14
5

6 15

7 16

8 17
9 18

19

20
10

1. LED Druckschalter linker Behälter 1. Left tower pressure switch LED:

Ein= Kontakt geschlossen; Aus= Kontakt geöffnet On= switch closed; Off= switch open
2. LED linker Behälter trocknet 2. Left tower drying LED
3. LED Regenerationsventil links 3. Left purge valve LED:
Ein= Ventil offen; Aus= Ventil geschlossen On= valve open; Off= valve closed
4. LED Eintrittsventil links 4. Left inlet valve LED:
Ein= Ventil offen; Aus= Ventil geschlossen On= valve open; Off= valve closed
5. LED linker Behälter regeneriert 5. Left tower regenerating LED
6. LED Service/ Wartung Filter 6. Filter service/ maintenance LED
7. Textdisplay 7. Text display
8. Wahlschalter Betriebsmodus 8. Operating mode selector switch
9. LED Spannung Ein 9. Power On LED
10. Ein/Aus-Schalter 10. Power On/ Off switch
11. LED Service/ Wartung Filter 11. Filter service/ maintenance LED
12. LED Druckschalter rechter Behälter 12. Right tower pressure switch LED:
Ein= Kontakt geschlossen; Aus= Kontakt geöffnet On= switch closed; Off= switch open
13. LED rechter Behälter trocknet 13. Right tower drying LED
14. LED Regenerationsventil rechts 14. Right purge valve LED:
Ein= Ventil offen; Aus= Ventil geschlossen On= valve open; Off= valve closed
15. LED rechter Behälter regeneriert 15. Right tower regenerating LED
16. LED Eintrittsventil rechts 16. Right inlet valve LED:
Ein= Ventil offen; Aus= Ventil geschlossen On= valve open; Off= valve closed
17. ENTER-TAste 17. Enter switch
18. LED Service-/Wartungs-Erinnerung 18. Maintenance/ service reminder LED
19. LED Alarm 19. Alarm LED
20. RESET-Taster zum quittieren bei Alarm und Wartungserin- 20. Reset switch for alarm and maintenance reminder
nerungen. 21. Pressure gauge left tower
21. Manometer linker Behälter 22. Pressure gauge right tower
22. Manometer rechter Behälter 23. Pressure gauge orifice pre-pressure
23. Manometer Blendenvordruck 24. Filter monitor pre-filter
24. Filtermonitor-Vorfilter 25. Filter monitor after-filter
25. Filtermonitor-Nachfilter

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 5. Störungen, 5. Malfunctions,
Störungsbeseitigung troubleshooting

Hinweis: Remark!
Die in Klammern näher bezeichneten Bauteile (z.B. The component specified in parentheses (e.g. B006)
B006) beziehen sich auf das R&I-Schema. refer to the R&I schematic diagram.

5.1 Störungen ohne Störmeldung 5.1 Malfunctions without fault messages

Wasser im Druckluftsystem Water in the compressed-air system

Mögliche Ursache: Possible cause:

a) Kondensatrückstände im Druckluftnetz, die sich bereits vor a) Condensate residues which formed prior to starting up the
der Inbetriebnahme gebildet hatten. dryer are in the compressed-air system.

b) Umgehungsleitung Bypass geöffnet. b) Bypass open.

c) Kondensat des Vorfilters wird nicht abgeschieden. c) Condensate from the pre filter not separated.

d) Die Betriebsbedingungen haben sich seit der Installation des d) The operating parameters altered since the desiccant dryer
Trockners geändert. was installed.

Störungsbeseitigung: Remedy:

a) Druckluftnetz mit trockener Luft ausblasen, bis keine Feuchtig- a) Blow out compressed-air system with dry air until no more
keit mehr auskondensiert. Entnahmestelle möglichst am ent- moisture is condensed out. Open collection point at most
ferntesten Punkt öffnen. remote position, if possible

b) Bypass schließen. b) Close bypass.

c) Durch Fachpersonal überprüfen und ggf. instandsetzen c) Carry out check by trained staff and repair, if necessary.
lassen.
d) Correct the operating parameters as the dryer layed out.
d) Betriebsbedingungen für die der Trockner ausgelegt wurde
wieder herstellen.

High pressure loss through

Hoher Druckverlust über den the desiccant air dryer
Adsorptionstrockner
Possible cause:
Mögliche Ursache:
a) The capacity of the pre- and/or -after filter cartridge are
a) Vor- und/oder Nachfilterelemente sind am Ende ihrer Aufnah- overload.
mekapazität.

Störungsbeseitigung: Remedy:

a) Austausch der Filterelemente siehe Filter-Bedienungsanlei- a) For replacing the filter cartridges see instruction manual filter.
tung

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 5. Störungen, 5. Malfunctions,
Störungsbeseitigung troubleshooting

Hinweis: Remark!
Die in Klammern näher bezeichneten Bauteile (z.B. The component specified in parentheses (e.g. B006)
B006) beziehen sich auf das R&I-Schema. refer to the R&I schematic diagram.

5.2 Störungen mit Störmeldung 5.2 Malfunctions with fault messages

„Schaltfehler“ Leuchtdiode 19 blinkt „Switching failure“ light emitting diode 19

(siehe Kapitel 4.5) flashing. (see section 4.5)
Mögliche Ursache: Possible cause:

a) Restdruck zu hoch (Schalldämpfer verstopft). a) Residual pressure too high (Purge muffler clogged).

b) Wechselventil (V013) arbeitet nicht einwandfrei. b) Shuttle valve (V013) works not right.

c) Druckschalter (PS028, PS029) defekt. c) Pressure switch (PS028, PS029) defective.

Störungsbeseitigung: Remedy:

a) Austausch der Schalldämpfer (siehe Abschnitt 11.1 a) Replace the purge muffler (see section 11.1
„Wöchentliche Wartungsarbeiten). „Weekly maintenance“).

b) Durch geschultes Fachpersonal überprüfen und ggf. b) Carry out check by trained staff and repair, if necessary.
instandsetzen lassen.
c) Carry out check by trained staff and repair, if necessary.
c) Durch geschultes Fachpersonal überprüfen und ggf.
instandsetzen lassen.

Hinweis! Remark!
Zum Quittieren der Störungsmeldung die Taste To reset a malfunction press the button „RESET“
„RESET“ (Taste 20) betätigen. (button 20).

Hinweis! Remark!
Zum Anschluß externer Störmeldesysteme ist das For the connection of external trouble indication
Gerät mit einem potentialfreien Kontakt „Sammel- systems the dryer is equipped with a potential free
störmeldung“) ausgerüstet. Den Anschluß entneh- contact „common alarm“. For connections please
men Sie bitte dem Schaltplan (siehe Kapitel 14). see the wiring diagram (chapter 14).

Hinweis! Remark!
Bei fehlendem Druckaufbau im regenerierenden Be- With missing pressure build-up in the regenerating
hälter, verbleibt die Steuerung im anstehenden Zy- vessel, the dryer will not switch towers. The
klus, d.h. die Trocknung erfolgt nur noch in einem switching failure alarm will be activated and the
Behälter. Der Schaltfehleralarm wird ausgelöst. dryer will remain in this mode until the tower
repressurizes.

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 6. Transport, Anlieferung 6. Transport, delivery,
Wareneingangskontrolle Checking of goods received

6.1 Transport 6.1 Transport

Der Adsorptionstrockner ist vorbereitet für den Transport mit The desiccant compressed air dryer is prepared for transport
einem Gabelstapler. Wenn Sie das Gerät installieren, bewegen with a fork-lift truck. When installing the dryer, move it with a
Sie es mit einem Gabelstapler oder anderen geeigneten Vorrich- fork-lift truck or another suitable device. The desiccant
tungen. Der Adsorptionstrockner darf auf keinen Fall an den compressed air dryer must by no means be lifted at the mounted
montierten Rohrleitungen angehoben werden. Ernsthafte Beschä- pipes. Severe damage may result from such handling.
digungen können hieraus resultieren.

6.2 Anlieferung 6.2 Delivery

Der Adsorptionstrockner ist sorgfältig geprüft und verpackt wor- The desiccant compressed air dryer is thoroughly checked and
den, bevor er das Herstellerwerk verlassen hat. Er ist im ein- packed, before it leaves the factory. It has been handed over to
wandfreien Zustand dem Spediteur übergeben worden. the forwarding agent in perfect condition.

6.3 Wareneingangskontrolle 6.3 Checking at Receipt

Überprüfen Sie die Verpackung auf sichtbare Beschädigungen. Upon receipt please check immediately the packing for visible
Bestehen Sie im Falle einer sichtbaren Beschädigung darauf, damage. In case of visible damage of the packing, please insist
daß auf dem Ablieferungsnachweis des Spediteurs ein entspre- upon a respective note on the delivery sheet of the forwarding
chender Vermerk gemacht wird. agent.
Überprüfen Sie das Gerät auf verdeckte Beschädigungen. Wur- Please also check the dryer for hidden damages. If a desiccant
de der Adsorptionstrockner mit augenscheinlich unbeschädigter compressed air dryer is delivered with apparently undamaged
Verpackung aber verdeckten Beschädigungen angeliefert, so packing but with hidden damage, see to it, that the forwarding
verständigen Sie unverzüglich den Spediteur und veranlassen agent is informed at once and have the dryer inspected.
eine Begutachtung des Adsorptionstrockners.
The manufacturer is not responsible for damages occurred
Für Beschädigungen während des Transportes ist der Herstel- during transport.
ler nicht verantwortlich.

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 7. Aufstellung und Montage 7. Installation and mounting

7.1 Aufstellungsort 7.1 Location of Installation

Der Adsorptionstrockner sollte in einem trockenen Innenraum auf- The desiccant compressed air dryer should be installed in a dry
gestellt werden. room indoors. Ample free space should be allowed for the
Zur Wartung der Anlage ist es dringend erforderlich, daß genü- maintenance of the device.
gend Freiraum vorhanden ist. The desiccant compressed air dryer should be installed on a
Die Aufstellung soll auf einer ebenen, geraden Fläche erfolgen. straight and even floor.
Spezielle Fundamente zur Aufstellung des Adsorptionstrockners Special foundation for the installation of the desiccant compressed
sind nicht erforderlich. air dryer are not necessary.
Die Umgebungstemperatur entnehmen Sie bitte dem Kapitel 12. For the ambient temperature please see chapter 12.
"Technische Daten". This product is not designed for earthquake endangered
Das Gerät ist nicht für einen Betrieb in erdbebengefährdeten areas!
Regionen geeignet! The dryer must not operate in corrosive atmospheres!
Der Trockner darf nicht in korrosiver Atmosphäre betrieben wer-
den!

7.2 Montage 7.2 Mounting

ACHTUNG! CAUTION!
Ist ein Absperrorgan im Druckluftausgang des When a valve is installed after the dryer an
Trockners installiert, sollte ein Sicherheitsventil appropriate safety relief valve should be installed
installiert werden, welches einen durch äußere Ein- to prevent over pressurization of the dryer due to
flüsse (z.B. Feuer) hervorgerufenen Überdruck ab- external causes (fire).
leiten kann.

CAUTION!
ACHTUNG! When installing the dryer ensure all connections
Achten Sie bei der Montage darauf, daß keine Zug- are even and no pressure is placed on inlet and
und Druckkräfte auf die Geräteanschlüsse übertra- outlet connections.
gen werden.

ACHTUNG! Caution!
Überprüfen Sie alle druckluftführenden Verbindun- Check all compressed-air connections to ensure
gen auf Festigkeit und Dichtigkeit. that they are firm and free of leaks.

7.3 Anschluß an das Druckluftnetz 7.3 Connection to the compressed air system
Die Druckluftein- und -austrittsleitung sollte mit Absperrorganen The compressed air inlet and outlet line should be equipped with
(z.B. Ventile, Kugelhähne, Klappen), sowie mit einem Bypass shut off valves and a by-pass system.
versehen werden. For the sizing of the connections please see chapter 12. “Technical
Die Dimensionierung der Anschlüsse entnehmen Sie bitte dem Data“.
Kapitel 12. „Technische Daten“.

7.4 Vor- und Nachfilter 7.4 Pre- and -after filter

Achtung! Caution!
Um eine einwandfreie Funktion des Gerätes zu ge- In order to ensure correct functioning of the
währleisten, muß in der Zuleitung ein Ölfeinfilter desiccant dryer, it must be installed a oil removal
mit max. zulässigem Restölgehalt von 0,01 ppm in- filter with a max. residual oil of 0,01 ppm (if not
stalliert werden (wenn nicht vorhanden). installed).
Zum Schutz der nachfolgenden Rohrleitungs- To protect the down-line system from desiccant
systeme vor Adsorptionsmittelabrieb ist ein Staub- dust, a dust filter must be installed.
feinfilter zu installieren.

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 7. Aufstellung und Montage 7. Installation and Mounting

7.5 Kondensatableitung 7.5 Condensate drain

Für die Kondensatableitung ist ein Anschluß vorhanden: For the condensate drain two connection are provided:

• Automatischer Kondensatablaß des Vorfilters. • Automatic drain from the pre filter.

Die Dimensionierung des Anschlußes entnehmen Sie bitte Kapi- The sizing of the connection please see in chapter 12. "Technical
tel 12 "Technische Daten". Data".

Achten Sie bei der Montage der Kondensatableitung When fitting the drain please see to it, that the
darauf, daß das vom Vorfilter abgeschiedene Kon- condensate separated by the pre filter is drained
densat ungehindert abfließen kann. off into a system that does not create a back
pressure.
Hinweis!
Bei der Entsorgung des Kondensates ist der Instruction!
Schmutzanteil zu berücksichtigen. When disposing of the condensate the amount of
Beachten Sie die jeweils geltenden gesetzlichen pollution has to be taken into consideration. Please
Vorschriften. act according to the prevailing regulations of law.

7.6 Elektroanschluß 7.6 Electrical Connection

Die Klemmleiste für die Elektrozuleitung befindet sich im Schalt- The terminal block for the electrical connections is situated within
schrank. the switched cabinet.
Die elektrotechnischen Anschlußdaten entnehmen Sie bitte dem The electro-technical connection data are to be taken from chapter
Kapitel 12. „Technische Daten“. 12. "Technical Data".

Hinweis! Remark!
Zum Anschluß externer Störmeldesysteme ist das For the connection of external trouble indication
Gerät mit einem potentialfreien Kontakt „Sammel- systems the dryer is equipped with a potential free
störmeldung“) ausgerüstet. Den Anschluß entneh- contact „common alarm“. For connections please
men Sie bitte dem Schaltplan (siehe Kapitel 14). see the wiring diagram (chapter 14).

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 8. Erste Inbetriebnahme 8. Initial start-up
Inbetriebnahme nach längerem Start up after prolonged
Stillstand inoperative periods

8.1 Bedingungen 8.1 Preconditions

Der Trockner ist einschaltbereit wenn: The refrigerated compressed air-dryer is ready
for operation when:
• Das Gerät entsprechend Kapitel 7. „Aufstellung und Mon-
tage“ installiert wurde. • The device has been installed in accordance with section
7. „Installation and mounting“.
• Alle Zu- und Ableitungen sachgerecht angeschlossen
sind. • All inlet and outlet lines have been correctly connected.

• Die erforderlichen Energien (Elektro; Druckluft) verfüg- • The required forms of energy (electricity, compressed-
bar sind. air) are available.

• Absperrorgane (z.B. Ventile, Kugelhähne, Klappen) in • The shut-off devices (e.g. valves, ball valves, butterfly
der Druckluftein- und -austrittsleitung geschlossen sind valves) in the compressed-air inlet and outlet lines are
(wenn vorhanden). closed (if installed).

• Der Druckluft-Bypass geöffnet ist (wenn vorhanden). • The compressed-air bypass is open (if installed).

• Kondensat durch die Kondensatableitung ungehindert ab- • The condensate is able to flow through the condensate
fließen kann. discharger without obstruction.

• Das Gerät ist an das elektrische Spannungs- • The device has been connected to the electric power
versorgungsnetz mit der richtigen Betriebsspannung an- supply system with the correct operating vaoltage.
geschlossen.
Hinweis!
Hinweis! The switching failure alarm will activate if dryer is
Der Schaltfehleralarm wird ausgelöst, wenn der energized without being pressurized. Keep sure
Trockner eingeschaltet wird ohne das Betriebs- that the dryer has been correctly connected to the
druck anliegt. Stellen Sie sicher das der Trockner air pressure system and switch on the dryer again.
vor Inbetriebnahme ordnungsgemäß an die Druck- To reset the malfunction press the button „RESET“.
luft angeschlossen ist und starten Sie die Anlage
erneut oder quittieren Sie die Fehlermeldung mit
dem RESET-Taster (hierzu muß der Trockner unter
Druck stehen).
8.2 Switching on the dryer
The device is to be switched on only when all the
conditions specified in section 8.1 have been full-
8.2 Einschalten filled.

Gerät nur einschalten, wenn alle Bedingungen Open slowly the shut-off device in the compressed-air
des Abschnittes 8.1 erfüllt sind. inlet line.

Langsam das Absperrorgan in der Druckluftzuleitung Press the „I/0“ button.

öffnen.

Taster „I/0“ betätigen. Adjust of the pre-pressure at purge air orifice see
section 8.3.

Einstellen des Vordruckes an der Regenerationsluftblende The dryer must regenerated for approx. 6 hours without
gemäß Abschnitt 8.3. compressed-air being supplied to the network.
After 6 hours during appropriate attitude a dew point under
Der Trockner muß ca. 6 Stunden regenerieren, ohne daß pressure close -40°C is reached. For a dew point under
Druckluft dem Druckluftnetz zugeführt wird. pressure of -70°C at least 1 week should be taken into
Nach 6 Stunden wird bei entsprechender Einstellung ein account!
Drucktaupunkt nahe -40°C erreicht. Für einen Drucktaupunkt
von -70°C sollte mindestens 1 Woche eingeplant werden! Open slowly the shut-off device in the compressed-air
outlet line.
Absperrorgan in der Druckluftaustrittsleitung langsam
öffnen. Close the compressed-air bypass.

Druckluft-Bypass schließen. The dryer is now OPERATIVE.

Please refer to section 4.3 „Operation“.
Der Adsorptionstrockner ist nun in BETRIEB.
Beachten Sie bitte den Abschnitt 4.3 "Betrieb".

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 8. Erste Inbetriebnahme 8. Initial start-up
Inbetriebnahme nach längerem Start up after prolonged
Stillstand inoperative periods

Hinweis! Remark!
Die Standardblenden sind für minimal 5 bar und The standard purge air orifices extended to min. 5
maximal 10 bar und für den Betrieb -70°C/ ISO Klas- bar and max. 10 bar and for the adjustment -70°C/
se 1 ausgelegt. Die Blenden für max. Betriebsdruck ISO class 1. The purge air orifices for working
16 bar sind am Trockner befestigt und müssen bei pressure max. 16 bar are fixed to the dryer and
Bedarf ausgewechselt werden. (Die Bohrungen der must change if necessary. (The boreholes for the
R-Blende 1 sind größer als die der R-Blende 2). R-orifice 1 is greater than the R-orifice 2).

8.3 Einstellen des Druckes vor der

8.3 Adjust the pressure at purge air orifice
Regenerationsluftblende
Remark!
Hinweis! The valve (V034) for adjusting the purge air flow is
Das Ventil (V034) zur Einstellung der Regenerations- positioned within the dryer case. The behind screen
luftmenge befindet sich innerhalb des Gehäuses. (1) must be remove.
Das hintere Gehäuseblech (1) muß entfernt wer-
den.

Bestimmende Werte: Determined values:

1. Maximaler Betriebsdruck des Trockners 1. Maximum working pressure of the dryer
2. Minimaler Betriebsdruck der Druckluft am Trocknereintritt 2. Minimum working pressure at inlet to dryer
3. Einstellung der Zykluszeit 3. Cycle time setting
Einstellung des Drucks vor der Regenerationsluftblende ISO Klassen 2; 3; 4 (DTP: -40°C/ -20°C; +3°C)
Adjustment of pressure at purge air orifice at ISO Klassen 2; 3; 4 (DTP: -40°C/ -20°C; +3°C)

Eintrittsdruck (bar) / Inlet pressure (bar)

Regenerationsluftdruck (bar)
Purge air pressure (bar)
5-7 8 9 10 11 12 13 14-16

R-Blende 1
R-orifice 1
3,1 2,9 2,8 2,7 - - - -

R-Blende 2
R-orifice 2
5,8 5,7 5,5 5,3 5,2 5,0

Einstellung des Drucks vor der Regenerationsluftblende ISO Klasse 1 (DTP: -70°C)
Adjustment of pressure at purge air orifice at ISO Klasse 1 (DTP: -70°C)

Eintrittsdruck (bar) / Inlet pressure (bar)

Regenerationsluftdruck (bar)
Purge air pressure (bar)
7 8 9 10-11 12-13 14-16

R-Blende 1
R-orifice 1
4,7 4, 4 4,3 4, 1 3,9 3,7

Stellen Sie das Ventil (V 034) so ein, daß der Regenera- Adjust the valve (V 034) until purge air pressure gauge
tionsluftdruck am Manometer (PI 035) mit dem benötigten (PI 035) reads required pressure setting.
Wert übereinstimmt.
Remark!
HINWEIS! Adjustment must be made while a dryer is purging
Die Einstellung muß erfolgen, wenn der Trockner the right vessel (LED15 see page 14) (air exhausting
den rechten Behälter (LED15 siehe Seite 14) regene- from the right muffler).
riert! (Luft strömt aus dem rechten Schalldämpfer).

ACHTUNG! ATTENTION!
Eine zu geringe Menge Regenerationsluft kann zum Insufficient purge air will eventually result in
Durchfeuchten des Trockenmittels führen. Der ge- saturation of desiccant bed and wet air
forderte Taupunkt wir dann nicht mehr erreicht. Stel- downstream. Make certian that cycle time, purge
len Sie sicher, daß die Zykluszeit, der Regenera- economizer switch and purge pressure are
tionsluft-Sparmodus und der Vordruck der Regen- correctly set.
erationsluft vor der Blende richtig eingestellt sind.

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 8. Erste Inbetriebnahme 8. Initial start-up
Inbetriebnahme nach längerem Start up after prolonged
Stillstand inoperative periods

8.4 Austausch der Regenerationsluftblende 8.4 Exchange of the orifices

Die „R-Blende 1“ ist werksseitig eingebaut. Sie wird grundsätz- The „R-orifice1“ is mounted by the manufacturer. This orifice are
lich im 4 Minuten Zyklus (-70°C) benutzt und kann bis 10bar general used in the 4 minute cycle (-70°C) and can used until
Betriebsdruck in den anderen Zykluszeiten benutzt werden. Die 10bar working pressure in the other cycle times. The „R-orifice
„R-Blende 2“ wird nicht im 4 Minuten Zyklus (-70°C) benutzt, sie 2“ is not used in the 4 minutes (-70°C) cycle, they can used by
kann in den anderen Zykluszeiten ab 9 bar Betriebsdruck ver- working pressure not less from 9 bar (see table in chapter 8.3).
wendet werden (siehe Tabelle in Kapitel 8.3). Remove the back side panels. For exchange the orifices remove
Entfernen Sie die Bleche an der Rückwand. Für den Austausch the regeneration pipe by unfasten the screw coupling (1). In the
der Blenden wird die Regenerationsleitung an den Überwurf- screw couplings are the orifices. The orifices must change
verschraubungen (1) gelöst, und dort die eingelegten Blenden pairwise.
getauscht. Die Blenden müssen immer paarweise getauscht
werden! .
The orifices (2) for changing are below the pressure gauge.
Das Tauschblendenpaar (2) befindet sich unterhalb des Mano-
meters.

1) Installierte Blenden 1) Mounted orifices

2) Alternativ Blendensatz 2) Alternative orifice set

8.5 Drucktaupunkt wählen 8.5 Select the pressure dewpoint

Die Anwahl der Taupunktklasse (Kap. 9.6.1) bestimmt die Zyklus- The selection of the dew point class (chapter 9.6.1) determines
zeit the cycle time

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.1 Anschlüsse - ECO-CONTROL 9.1 Connections - ECO-CONTROL

9.1.1 Anschlüsse – Sammelstörmeldung 9.1.1 Connections – Common Alarm Contacts

Klemmleiste
Terminal

NO
NC
C
ALARM
CONTACTS
Spannung

Spannung
Power

Power
1

1
0

0
COM

COM
NO

NO
NC

NC

max. 250V / 5A max. 250V / 5A

ALARM ALARM

9.1.2 Alarme 9.1.2 Common Alarm Relay Logic

Steuerspannung? Steuerung Ein Alarm oder Alarm Relais Alarm N.O. Alarm N.C.
oder Aus? Wartungsmeldung

Power to Controller on or Alarm or service Alarm relay Alarm N.O. Alarm N.C.
Controller? off? reminder coil contact contact

Abgefallen Offen Geschlossen

Nein / No - -
De-energized Open Closed

Angezogen Geschlossen Offen

Ja / Yes Aus / Off -
Energized Closed Open

Angezogen Geschlossen Offen

Ja / Yes Ein / On Nein / No
Energized Closed Open

Abgefallen Offen Geschlossen

Ja / Yes Ein / On Ja / Yes
De-energized Open Closed

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.1.3 Anschlüsse – Fern-EIN/AUS 9.1.3 Connections – Remote ON / OFF

Klemmleiste
Terminal

Fern-EIN/AUS Fern-EIN/AUS
Remote-ON/OFF REMOTE-ON/OFF

2 14 2 14

5 16 5 16

Blinklicht 5 = regeneriert / regenerating (gelb/ yellow)

Flashing light 2 = trocknet/ drying (grün/ green)
AUS 16 = regeneriert/ regenerating (gelb/ yellow)
OFF
14 = trocknet/ drying (grün/ green)

1 1

Fern-EIN/AUS
Remote ON/OFF
0 0
1 1
Trockner laufender Halbzyklus neuer Halbzyklus
Dryer current half cycle new half cycle

0 0

STOPP START
Halbzyklus Halbzyklus

Die Fern Ein/Aus Funktion kann nur bei eingeschaltetem The remote on/off function is only available if the dryer is
Trockner genutzt werden. in ON-position.

Anmerkung: Fern-EIN/AUS wird abgeschaltet, wenn der Note: Remote on/off is disabled when the dryer is in the
Trockner sich im Test-Zyklus befindet. Befindet sich der Manual cycle operation mode. When the dryer is in the
Trockner im Fernstopzustand, bleiben der EIN/AUS-Schal- remote stop state, only the power on/off switche is with
ter im Frontpanel als einziger aktiv. function.

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.1.4 Anschlüsse-Alarm hoher Taupunkt 9.1.4 Connections-High humidity or dewpoint alarm

Der normalerweise geschlossene potentialfreie Kontakt für ho- The normally closed dry contacts from a high humidity or dew
hen Taupunkt kann zu den AUX 1 Anschlusspunkten verdrahtet point alarm device can be wired to AUX 1 terminals. A shorting
werden. Wird der pot. freie Kontakt genutzt, muß die Drahtbrücke jumper that connects the two terminals must be removed if an
entfernt werden. Eine Unterbrechung der Verbindung zwischen alarm device is wired to the terminals. When continuity between
den Klemmen verursacht einen Taupunktalarm (vgl. Kapitel 9.7, the terminals is broken, the controller displays an outlet dew
Screens 17 und 18). Werden die AUX 1 Klemmen benutzt, kann point alarm (refer to Section 9.7, screens 17 and 18). If the AUX1
der optionale Taupunktsensor (-90°C ... +10°C/ 4 ... 20mA) nicht terminals are in use, then the optional dew point sensor
benutzt werden (siehe 9.2). (-90°C ... +10°C/ 4 ... 20mA) cannot be used (siehe 9.2)).

9.2 Jumper auf der Steuerplatine – 9.2 Control Board Jumpers –

ECO-CONTROL ECO-CONTROL

Max. Betriebsdruck
Max. operating press.
5,0 - 10,0 bar
JP1 Max. Betriebsdruck
Max. operating press.
9,0 - 16,0 bar
Keine Kondensatableiter installiert
No electric drains installed
JP2
Kondensatableiter * installiert
Drain 2 switch Drain 2 switch
2 2
Drain 2 switch Drain 2 switch

Electric drains * installed Drain 1 switch

Drain 1 switch
1
Drain 2 switch
Drain 2 switch
1

Kein Taupunktsensor installiert Aux 2 +

No dewpoint sensor installed Aux 2 C
JP3
Taupunktsensor * installiert Aux 2 + TP
Dewpoint sensor * installed Aux 2 C
Kein Drucksensor Drucklufteintritt installiert Aux 3 +
No pressure sensor air inlet installed Aux 3 C
RS232 J3 JP4
JP1
Drucksensor * Drucklufteintritt installiert Aux 3 + P
JP2 Pressure sensor * air inlet installed Aux 3 C
JP3
JP4
JP5 Kein Temp. sensor Drucklufteintritt installiert Aux 4 +
JP6 No temp. sensor air inlet installed Aux 4 C
JP7
JP8 JP5
Temp. sensor * Drucklufteintritt installiert Aux 4 + T
Temp. sensor* air inlet installed Aux 4 C
Nicht belegt
JP6 Not used
Nicht belegt
.............
.............
AUX4 C

AUX3 C

AUX2 C

AUX1 C
RBTH +

JP7
AUX4 +

AUX3 +

AUX2 +

AUX1 +

Not used
Analogeingang Digitaleingang Nicht belegt
Hoher Taupunkt JP8 Not used
Hoher Taupunkt
(Nicht nutzbar, Brücken, wenn
wenn AUX2 benutzt
AUX1 belegt)
Analog input Digital input *OPTION !
High dewpoint High dewpoint
(Not usable, Short terminals, if
if AUX1 is used) AUX 2 is used

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.3 Bedienelemente 9.3 Controls

9.3.1 EIN/AUS-Schalter 9.3.1 Dryer On / Off Switch

Vorsicht: Bei Spannungsausfall öffnen beide Einlaß- Caution: In the event of a loss of power, either in-
ventile und die beiden Regenerations-Druck- tentional or unintentional, both inlet-switching
entlastungsventile schließen. Der gerade regene- valves will open and both purge-repressurization
rierende Behälter wird bei Spannungsausfall einem valves will close. A tower that is actively purging
schnellen Druckaufbau ausgesetzt, der zur when the power off button is actuated will be
Fluidisierung und damit verbundenem Abrieb des subjected to a rapid repressurization that can lead
Trockenmittels führen kann. Der Trockner darf nur to fluidization and subsequent abrasion of the
am Ende eines jeden Halbzyklus abgeschaltet wer- desiccant bed. Ideally, dryers should be powered
den, wenn beide Trockenmittelbehälter unter vol- off at the end of any half cycle when both desiccant
lem Betriebsdruck stehen. towers are at full operating pressure.

9.4 Ereignisabfolge und Komponentenstatus 9.4 Front Panel Operation

Betriebsarten: Operating modes:

a) Programmmodus (Kapitel 9.5) a. Program Mode (chapter 9.5)

b) Setup-Modus (Kapitel 9.6) b. Setup Mode (chapter 9.6)
c) Alarm- und Servicemodus (Kapitel 9.7) c. Alarm & Service Mode (chapter 9.7)
d) Displaymodus (Kapitel 9.8) d. Display Mode (chapter 9.8)
e) Testmodus (Kapitel 9.9) e. Test Mode (chapter 9.9)

9.5 Programmmodus 9.5 Program Mode

Display-Modus
Display-mode

}
min. 3sec.

gleichzeitig
continously

Programm-Modus
Program-mode

Programm-Modus
Program-mode

Letzter Screen Beliebiger Screen

Last screen Any screen
min. 3sec. min. 60sec.

Display-Modus
Display-mode

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.5.1 Screen 1 – Anwahl der Sprache 9.5.1 Screen 1 – Select the language

_________________________ _________________________
DEUTSCH ENGLISH

• „Mit der Taste Sprache anwählen: • Press to select language:

Englisch, Deutsch, Französisch, Spanisch und Italienisch. ENGLISH, DEUTSCH, FRANCAIS, ESPANOL, and ITALIANO.

• Danach Taste drücken, um die Anwahl zu speichern • When finished, press to save the selection and
und zu Screen 2 überzugehen. move to Screen 2.

9.5.2 Screen 2 – Auto-Neustartmodus 9.5.2 Screen 2 – Auto restart mode

Beim „Automatischen Neustart“ startet der Trockner nach einem With the „Auto restart mode“ the dryer starts after a voltage
Spannungsausfall, falls er eingeschaltet war, automatisch. failure, if it were switched on, automatically.

AUTOM. NEUSTART_________ AUTO RESTART___________

AUS DISABLED

• Taste drücken, um zwischen NICHTFREIGABE und • Press to toggle between DISABLED and ENABLED.
FREIGABE zu wechseln.

• When finished, press to save the selection and move

• Danach Taste drücken, um die Anwahl zu speichern
to Screen 3 (if a dew point sensor is connected to AUX2) or
und zu Screen 3 (wenn ein Taupunktsensor an AUX2 an- Screen 4 (if one is not).
geschlossen ist) oder Screen 4 (falls nicht) überzugehen.

9.5.3 Screen 3 – Alarmpunkt für Taupunktsensor einstel- 9.5.3 Screen 3 – Alarm point for dew point sensor
len (AUX2, analoger Eingang) (AUX2, analog input)

TAUPUNKTALARM__________ DEW POINT ALARM_______

±XX°C ±XXX°F ±XX°C ±XXX°F

• Taste drücken, um die Einstellung des gewünschten • Press to increase or the ALARM RESET button to
Wertes zu erhöhen, oder den Resetknopf, um den ge- decrease the setting to the desired value.
wünschten Wert zu verringern. a. The default is –20°C –4°F .
a. Die Standardeinstellung ist -20 °C / -4 °F. b. The allowable range of values is from –75°C (–103°F)
b. Der erlaubte Bereich der Werte reicht von -75 °C (-103 to +10°C (+50°F) .
°F) bis +10 °C (+50 °F).

• When finished, press to save the selection and

• Danach Taste drücken, um die Anwahl zu speichern
move to Screen 4.
und zu Screen 4 übergehen.

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.5.4 Screen 4 – Serviceebene 9.5.4 Mode Screen 4 – Service level.

SERVICE LEVEL____________ SERVICE LEVEL_______

NORMAL NORMAL

• Taste drücken, um zwischen NORMAL und • Press to toggle between NORMAL and SEVERE.
VERKÜRZT zu wählen

a. NORMALE Serviceintervalle sind: a. NORMAL service intervals are:

I. 4000 Stunden für Filter i. 4000 hours for filters
II. 8000 Stunden für Trockenmittel ii. 8000 hours for desiccant
III. 4000 Stunden für Ventile. iii. 4000 hours for valves
b. VERKÜRZTE Serviceintervalle sind: b. SEVERE service intervals are:
I. 2000 Stunden für Filter i. 2000 hours for filters
II. 4000 Stunden für das Trockenmittel ii. 4000 hours for desiccant
III. 2000 Stunden für Ventile. iii. 2000 hours for valves

• Anmerkung: Die Betriebsstunden zählen weiter, so • NOTE: Time continues to accumulate as long as
lange die Steuerung mit Spannung versorgt wird, power is supplied to the controller, whether the
wobei es egal ist, ob die Steuerung ein- oder aus- controller is switched on or off.
geschaltet ist.

• Danach Taste drücken, um die Anwahl zu speichern • When finished Press to save the selection and move
und übergehen zu Screen 5 (falls keine Filtermonitore in- to Screen 5 (if no filter monitors are detected) or Screen 6
stalliert sind) oder Screen 6 (falls 1 oder 2 Filtermonitore (if 1 or 2 filter monitors are detected).
eingebaut sind).

9.5.5 Screen 5 – Rücksetzung des Timers für Filter- 9.5.5 Screen 5 – Reset the timer for filter service.
service
SERV. FILTER_____________ FILTER SERVICE______
RESET? NEIN RESET? NO

• Taste drücken, um zwischen NEIN und JA zu • Press to toggle between NO and YES.

wechseln.
• When finished, press to acknowledge the selection
• Danach Taste drücken, um die Anwahl zu quittieren and move to Screen 6.
und zu Screen 6 überzugehen.

9.5.6 Screen 6 - Rücksetzung des Timers für 9.5.6 Screen 6 – Reset the timer for desiccant
Trockenmittelservice service.

SERV. TRMITTEL___________ DESICCANT SERVCE_______

RESET? NEIN RESET? NO

• Taste drücken, um zwischen NEIN und JA zu • Press to toggle between NO and YES.

wechseln.
• When finished, press to acknowledge the selection
• Danach drücken, um die Anwahl zu quittieren und zu and move to Screen 7.
Screen 7 überzugehen.

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.5.7 Screen 7 – Rücksetzung des Timers für Ventil- 9.5.7 Screen 7 – Reset the timer for valve service.
service
SERVICE VENTIL____________ VALVE SERVICRE_______
RESET NEIN RESET NO

• Taste drücken, um zwischen NEIN und JA zu • Press to toggle between NO and YES.

wechseln.
• When finished, press to acknowledge the selection
• Danach Taste drücken, um die Anwahl zu quittieren and move to Screen 8.
und zu Screen 8 überzugehen.

9.5.8 Screen 8 – Rücksetzung des Zählers für den 9.5.8 Screen 8 – Reset the valve cycle counter.
Ventilzyklus
ZYKLUSZÄHLER_____________ CYCLE COUNTER_______
RESET? NEIN RESET? NO

• Taste drücken, um zwischen NEIN und JA zu • Press to toggle between NO and YES.

wechseln.
• When finished, press to acknowledge the selection
• Danach Taste drücken, um die Anwahl zu quittieren and exit Program Mode .
und den Programmmodus zu verlassen.

9.6 Setup-Modus 9.6 Setup Mode

Display-Modus
Display-mode

min. 3sec.

Setup-Modus
Setup-mode

Setup-Modus
Setup-mode

Screen 2 oder 4 Beliebiger Screen

Screen 2 or 4 Any screen
min. 3sec. min. 60sec.

Anforderungszyklus
Demand cycle Manueller Zyklus
Manual cycle
Fester Zyklus
Fixed cycle

Display-Modus Test modus

Display-mode Test-mode

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.6.1 Screen 1 – Anwahl der Taupunktklasse 9.6.1 Screen 1 – Select the dew point class
ISO 8573 TP_____________ ISO 8573 DEW PT_______
2:-40°C/-40°F 2:-40°C/-40°F

• Taste drücken, um durch folgende Auswahlen zu • Press to scroll through the choices:
scrollen
1. -70 °C / -94 °F 1: -70°C/-94°F
2. -40 °C / -40 °F 2: -40°C/-40°F
3. -20 °C / -4 °F 3: -20°C/-4°F
4. +3 °C / +37 °F 4: +3°C/+37°F

• Danach Taste drücken, um die Anwahl zu quittieren • When finished, press to save the selection and
und zu Screen 2 überzugehen. move to Screen 2.

9.6.2 Screen 2 – Anwahl des Zyklustyps 9.6.2 Screen 2 – Select the cycle type
ZYKLUSTYP_____________ CYCLE TYPE________
BELADUNGSABH. DEMAND CYCLE

• Taste drücken, um durch die Wahlmöglichkeiten zu • Press to scroll through the choices: DEMAND CYCLE,
scrollen: FIXED CYCLE, and MANUAL CYCLE. Note: DEMAND CYCLE
BELADUNGSABHÄNGIGER ZYKLUS, FESTER ZYKLUS und is not available if Class 1 was selected in the previous
MANUELLER ZYKLUS. screen.
Anmerkung: Der BELADUNGSABHÄNGIGEZYKLUS ist nicht
verfügbar, falls im vorangegangenen Screen Klasse 1 an- • When finished, press to save the selection and
gewählt war.
move to Screen 3 (if the dryer has electric drains) or exit
Setup Mode (if the dryer does not have electric drains).
• Danach Taste drücken, um die Anwahl zu speichern
und zu Screen 3 überzugehen (falls der Trockner über
Kondensatableiter verfügt) oder den Setup-Modus zu verlas-
sen (falls der Trockner nicht über Kondsensatableiter verfügt).

9.6.3 Screen 3 – Kondensatableitertest (nicht ver-

fügbar) 9.6.3 Screen 3 – Test the drains (not available)

TEST ABLEITER?___________ TEST DRAIN?_______

NEIN NO

• Taste drücken, um zwischen NEIN und JA zu • Press to toggle between NO and YES.

wechseln.

• Taste drücken, um fortzufahren. • Press to continue.

a. Wurde NEIN angewählt, verlässt die Steuerung den a. If NO was selected, the controller immediately exits
Setup-Modus sofort. Setup Mode.
b. Wurde JA angewählt, aktiviert die Steuerung Ableiter 1 b. If YES was selected, the controller energizes Drain 1
und 2 vier Sekunden lang, bevor der Setup-Modus ver- and Drain 2 for 4 seconds before exiting Setup Mode.
lassen wird. (nicht verfügbar) (not available)

9.7 Alarm- und Servicemodus 9.7 Alarm & Service Mode

Der Alarm- und Servicemodus ist nur aktiv, wenn die Steuerung Alarm & Service Mode is active when the controller is in Display
im Displaymodus ist. Mode. It is not active in Program Mode, Setup Mode, or Test Mode.

Anzeigeprioritäten: Display priorities:

1. Störmeldungen 1. Alarm message
2. Servicemeldungen 2. Service message
3. Displaymeldungen 3. Display message

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.7.1 Störungen 9.7.1 Alarm messages

Störungen werden – mit einer Ausnahme - auf “first-out” Grund- Alarm messages are displayed on a first-out basis with one
lage angezeigt. Der Alarm, der durch einen offenen Druckschal- exception. The alarm caused by an open pressure switch at the
ter am Ende des Regenerationszyklus verursacht wird, hat Prio- end of the regeneration cycle, takes precedence over existing
rität gegenüber bestehenden Alarmen. Vgl. 9.7.1.1 (3). alarms. See 9.7.1.1 (3).

9.7.1.1 Druckschalteralarme 9.7.1.1 Pressure Switch Alarms

Es gibt für jeden Behälter drei Störmeldungen, die durch Druck- There are three alarms for each tower that are triggered by the
schalter ausgelöst werden. Diese Alarme können sowohl im Fes- tower pressure switches. These alarms can occur in either the
ten Zyklus als auch im Beladungsabhängigenzyklus ausgelöst fixed or demand cycle.
werden.
1. Linker oder rechter Behälter, trocknend, niedriger Druck 1. Left or right tower, drying, low pressure
• Druckschalter während des Trockenzyklus offen. • Pressure switch open during drying cycle
2. Linker oder rechter Behälter, regenerierend, hoher Druck 2. Left or right tower, regenerating, high pressure
• Druckschalter geschlossen, während das Regenerat- • Pressure switch closed while purge valve is open (after
ionsventil offen ist (nach anfänglicher Zeitverzögerung) an initial time delay)
3. Linker oder rechter Behälter, regenerierend, niedriger Druck 3. Left or right tower, regenerating, low pressure
• Druckschalter am Ende des Regenerierungszyklus offen. • Pressure switch open at the end of the regenerating
cycle

9.7.1.2 Thermosensor-Störungen 9.7.1.2 Thermistor Alarms

Es gibt zwei Alarme für jeden der vier Thermofühler. Diese Alar- There are two alarms for each of the four thermistors. These
me können nur im Beladungsabhängigenzyklus auftreten. alarms can only occur in the demand cycle.

1. Linker oder rechter Behälter, oberer oder unterer Sensor, 1. Left or right tower, upper or lower sensor, over-range
oberhalb des Meßbereiches. • Temperature above 150°F (66°C)
• Temperatur über 150 °F (66 °C) • Thermistor circuit shorted
• Thermosensor kurzgeschlossen 2. Left or right tower, upper or lower sensor, under-range
2. Linker oder rechter Behälter, oberer oder unterer Sensor, one cycle
unterhalb des Meßbereiches. • Temperature below 40°F (4°C)
• Temperatur unter 40 °F (4 °C) • Thermistor circuit open
• Sensorkreis offen

9.7.1.3 Optionale Vorrichtung Alarme 9.7.1.3 Optional Device Alarms

1. Kondensatableiter mit Alarmkontakten 1. Electric Drains with Alarm Contacts
• Wenn die Kontakte öffnen, wird eine Ableiterstörung • If the contacts open, then a drain alarm is indicated.
angezeigt. 2. Humistat (humidity sensor) - AUX 1 input
2. Feuchtigkeit (Feuchtigkeitssensor) – AUX1 Eingang • If the contacts open, the outlet dew point alarm is indicated.
• Wenn die Kontakte öffnen, wird der Ausgangstaupunkt- 3. Dew point sensor - AUX 2 analog input
alarm angezeigt. • The user enters an alarm value through the ECO-CONTROL
3. Taupunktsensor – AUX2 Analogeingang Program Mode.
• Der Bediener gibt einen Alarmwert im Programmodus der • If the measured dew point exceeds the alarm value, the
ECO-CONTROL-Steuerung ein. outlet dew point alarm is indicated.
• Liegt der gemessene Taupunkt höher als der Alarmwert,
wird die Störung Taupunkt angezeigt. When an alarm condition occurs follows.
• The alarm LED blinks and the appropriate alarm message
Tritt eine Störung auf folgt: is shown on the text display.
• Die Alarm-LED blinkt und die entsprechende Störung wird • The dryer continues to cycle normally (see below for
im Textdisplay angezeigt. exception).
• Der Trockner fährt mit dem normalen Zyklus fort (Ausnah- NOTE: The LEDs for the valves, pressure switches,
me siehe unten). and desiccant towers are not used for alarm
Anmerkung: Die LEDs für die Ventile, Druckschalter indication.
und Trockenmitteltürme werden nicht zur Alarm-
anzeige benutzt.

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

• Wird die Störung für einen Zyklus gelöscht, stoppt das • If the alarm condition clears for one cycle, then the alarm
Blinken der Alarm-LED (LED leuchtet kontinuierlich); die LED stops blinking (LED on); the alarm message continues
Alarmmitteilung wird weiterhin angezeigt. to be displayed.
• Ausnahme: Wird der Alarm durch einen Zustand in Kapitel • Exception: If the alarm is caused by the condition in Section
9.7.1.1 (1 oder 3) fehlender Druckaufbau verursacht, stoppt 9.7.1.1 (1 or 3) no pressure build up, then the cycle stops.
der Zyklus. Wurde der Alarmzustand korrigiert, geht das Once the alarm condition is corrected, the alarm LED stops
Blinken der LED in Dauerlicht über und der Zyklus wird blinking (LED on) and the cycle continues normally; the alarm
normal fortgesetzt. Die Störung wird weiterhin angezeigt. message continues to be displayed.
• Im Bedarfszyklus schaltet die Steuerung zu einem festen • In the demand cycle, the control switches to a fixed 10
10-Minuten-Zyklus, wenn die Alarm-LED zu blinken beginnt. minute cycle when the alarm LED begins blinking. Control
Dies gilt für den Druckschalter, den Thermosensor und die switches back to the selected demand cycle after the alarm
Taupunktalarme, nicht jedoch für die Kondensatableiter- condition clears. This applies to pressure switch, thermistor,
störung. and outlet dew point alarms, but not to drain alarms.
• Wurde die Störung beseitigt, Reset-Knopf drücken, um die • When the alarm condition is corrected, press the reset
Alarm-LED auszuschalten und die Störmeldung vom Text- button to extinguish the alarm LED and to clear the alarm
display zu löschen. message from the text display.

Für jede Störung wird folgendes im Display angezeigt. Die zwei- The following text display is shown for each alarm. The second
te Zeile der Alarmscreens enthält bis zu drei Mitteilungen, wel- line of the alarm screens contains up to three messages, which
che man durchscrollen kann, wobei jede drei Sekunden lang are scrolled through, displaying each one for 3 after the alarm
nach Löschen des Alarmzustandes angezeigt wird. condition clears seconds.

9.7.1.4 Alarmmodus Screen 1 – Linker Behälter 9.7.1.4 Alarm Mode Screen 1 – Left Tower Drying
trocknet - Niedrigdruck (offener Druckschalter- – Low Pressure (Open Pressure Switch Circuit)
kontakt)

ALARM ALARM
_______________________________________ _______________________________________

LINKER BEHÄLTER LEFT TOWER

TROCKNEN DRYING
NIEDRIGER DRUCK LOW PRESSURE

9.7.1.5 Alarmmodus Screen 2 – Linker Behälter re- 9.7.1.5 Alarm Mode Screen 2 – Left Tower
generiert - Hochdruck (geschlossener Druckschalter- Regenerating – High Pressure (Closed Pressure
kontakt) Switch Circuit)

ALARM ALARM
_______________________________________ _______________________________________

LINKER BEHÄLTER LEFT TOWER

REGENERIEREN REGENERATING
HOHER DRUCK HIGH PRESSURE

9.7.1.6 Alarmmodus Screen 3 – Linker Behälter re- 9.7.1.6 Alarm Mode Screen 3 – Left Tower
generiert - Niedrigdruck (offener Druckschalter- Regenerating- Low Pressure (Open Pressure Switch
kontakt) Circuit)

ALARM ALARM
_______________________________________ _______________________________________

LINKER BEHÄLTER LEFT TOWER

REGENERIEREN REGENERATING
NIEDRIGER DRUCK LOW PRESSURE

9.7.1.7 Alarmmodus Screen 4 – Linker Behälter, obe- 9.7.1.7 Alarm Mode Screen 4 – Left Tower, Upper
rer Sensor (Thermosensor) Wert unterhalb des Sensor (Thermistor) Under-Range
Meßbereiches

ALARM ALARM
_______________________________________ _______________________________________

LINKER BEHÄLTER LEFT TOWER

OBERER SENSOR UPPER SENSOR
UNTER MITTELWERT UNDER-RANGE

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.7.1.8 Alarmmodus Screen 5 – Linker Behälter, 9.7.1.8 Alarm Mode Screen 5 – Left Tower, Upper
oberer Sensor (Thermosensor) Wert oberhalb des Sensor (Thermistor) Over-Range
Meßbereiches

ALARM ALARM
_______________________________________ _______________________________________

LINKER BEHÄLTER LEFT TOWER

OBERER SENSOR UPPER SENSOR
ÜBER MITTELWERT OVER-RANGE

9.7.1.9 Alarmmodus Screen 6 – Linker Behälter, unte- 9.7.1.9 Alarm Mode Screen 6 – Left Tower, Lower
rer Sensor (Thermosensor) Wert unterhalb des Sensor (Thermistor) Under-Range
Meßbereiches

ALARM ALARM
_______________________________________ _______________________________________

LINKER BEHÄLTER LEFT TOWER

UNTERER SENSOR LOWER SENSOR
UNTER MITTELWERT UNDER-RANGE

9.7.1.10 Alarmmodus Screen 7 – Linker Behälter, unte- 9.7.1.10 Alarm Mode Screen 7 – Left Tower, Lower
rer Sensor (Thermosensor) Wert oberhalb des Sensor (Thermistor) Over-Range
Meßbereiches

ALARM ALARM
_______________________________________ _______________________________________

LINKER BEHÄLTER LEFT TOWER

UNTERER SENSOR LOWER SENSOR
ÜBER MITTELWERT OVER-RANGE

9.7.1.11 Alarmmodus Screen 8 - Rechter Behälter 9.7.1.11 Alarm Mode Screen 8 - Right Tower Drying
trocknet - Niedrigdruck (offener Druckschalter- – Low Pressure (Open Pressure Switch Circuit)
kontakt)

ALARM ALARM
_______________________________________ _______________________________________

RECHTER BEHÄLTER RIGHT TOWER

TROCKNEN DRYING
NIEDRIGER DRUCK LOW PRESSURE

9.7.1.12 Alarmmodus Screen 9 – Rechter Behälter 9.7.1.12 Alarm Mode Screen 9 – Right Tower
regeneriert - Hochdruck (geschlossener Druckschalter- Regenerating – High Pressure (Closed Pressure Switch
kontakt) Circuit

ALARM ALARM
_______________________________________ _______________________________________

RECHTER BEHÄLTER RIGHT TOWER

REGENERIEREN REGENERATING
HOHER DRUCK HIGH PRESSURE

9.7.1.13 Alarmmodus Screen 10 – Rechter Behäl- 9.7.1.13 Alarm Mode Screen 10 – Right Tower
ter regeneriert - Niedrigdruck (offener Druckschalter- Regenerating- Low Pressure (Open Pressure Switch
kontakt) Circuit)

ALARM ALARM
_______________________________________ _______________________________________

RECHTER BEHÄLTER RIGHT TOWER

REGENERIEREN REGENERATING
NIEDRIGER DRUCK LOW PRESSURE

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.7.1.14 Alarmmodus Screen 11 – Rechter Behälter, obe- 9.7.1.14 Alarm Mode Screen 11 – Right Tower,
rer Sensor (Thermosensor) Wert unterhalb des Upper Sensor (Thermistor) Under-Range
Meßbereiches

ALARM ALARM
_______________________________________ _______________________________________

RECHTER BEHÄLTER RIGHT TOWER

OBERER SENSOR UPPER SENSOR
UNTER MITTELWERT UNDER-RANGE

9.7.1.15 Alarmmodus Screen 12 – Rechter Behälter, obe- 9.7.1.15 Alarm Mode Screen 12 – Right Tower,
rer Sensor (Thermosensor) Wert oberhalb des Upper Sensor (Thermistor) Over-Range
Meßbereiches

ALARM ALARM
_______________________________________ _______________________________________

RECHTER BEHÄLTER RIGHT TOWER

OBERER SENSOR UPPER SENSOR
ÜBER MITTELWERT OVER-RANGE

9.7.1.16 Alarmmodus Screen 13 – Rechter Behälter, un- 9.7.1.16 Alarm Mode Screen 13 – Right Tower,
terer Sensor (Thermosensor) Wert unterhalb des Lower Sensor (Thermistor) Under-Range
Meßbereiches

ALARM ALARM
_______________________________________ _______________________________________

RECHTER BEHÄLTER RIGHT TOWER

UNTERER SENSOR LOWER SENSOR
UNTER MITTELWERT UNDER-RANGE

9.7.1.17 Alarmmodus Screen 14 – Rechter Behälter, un- 9.7.1.17 Alarm Mode Screen 14 – Right Tower,
terer Sensor (Thermosensor) Wert oberhalb des Lower Sensor (Thermistor) Over-Range
Meßbereiches

ALARM ALARM
_______________________________________ _______________________________________

RECHTER BEHÄLTER RIGHT TOWER

UNTERER SENSOR LOWER SENSOR
ÜBER MITTELWERT OVER-RANGE

9.7.1.18 Alarmmodus Screen 15 – 9.7.1.18 Alarm Mode Screen 15 – Alarm Drain 1

Alarm Kondensatableiter 1
ALARM ALARM
_______________________________________ _______________________________________

ABLEITER 1 DRAIN 1

9.7.1.19 Alarmmodus Screen 16 – 9.7.1.19 Alarm Mode Screen 16 – Alarm Drain 2

Alarm Kondensatableiter 2
ALARM ALARM
_______________________________________ _______________________________________

ABLEITER 2 DRAIN 2

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.7.1.20 Alarmmodus Screen 17 – Alarm 9.7.1.20 Alarm Mode Screen 17 – Alarm

ALARM ALARM
_______________________________________ _______________________________________

LINKER BEHÄLTER LEFT TOWER

TROCKNEN DRYING
TP. AM AUSTRITT OUTLET DEW POINT

9.7.1.21 Alarmmodus Screen 18 – Alarm 9.7.1.21 Alarm Mode Screen 18 – Alarm

ALARM ALARM
_______________________________________ _______________________________________

RECHTER BEHÄLTER RIGHT TOWER

TROCKNEN DRYING
TP. AM AUSTRITT OUTLET DEW POINT

9.7.2 Servicemeldungen 9.7.2 Service messages

Es gibt zwei Serviceebenen (normal und verkürzt), wie im There are two service levels (normal and severe) as described
Programmodus beschrieben. Jede Serviceebene verfügt über in Program Mode. Each service level has preset time intervals for
voreingestellte Zeitintervalle für Servicearbeiten an Filtern, servicing the filters, desiccant, and valves. Time continues to
Trockenmittel und Ventilen. Die Betriebszeit läuft weiter, solange accumulate as long as power is supplied to the controller, whether
die Steuerung mit Spannung versorgt wird, wobei es gleich ist, the controller is switched on or off.
ob die Steuerung ein- oder ausgeschaltet ist. When a service time interval expiresfollows:
Läuft ein Servicezeitintervall aus folgt:
• The service LED blinks and the appropriate service message
• Die Service-LED blinkt und die entsprechende Service- is shown on the text display. (See 9.7.1)
mitteilung wird auf dem Textdisplay angezeigt (vgl. 9.7.1). • When the service interval for filters has expired the two
• Wenn das Serviceintervall für Filter ausgelaufen ist, blinken filter LEDs also blink. NOTE: If the dryer has 1 or 2 filter
auch die zwei Filter-LEDs. Anmerkung: Falls der Trockner monitors, the timer for filter service is disabled. When the
über 1 oder 2 Filterüberwachungsgeräte verfügt, wird der filter monitor(s) sends an alarm signal (change filter) to the
Timer für die Filterwartung gesperrt. Wenn das/die ECO-CONTROL, the controller displays the same LEDs and
Filterüberwachungsgerät(e) einen Alarm an die ECO- messages it would if the timer for filter service had expired.
CONTROL-Steuerung sendet(n) (Filterwechsel), zeigt die • The dryer continues to cycle normally.
Steuerung dieselben LED‘s und Mitteilungen an, die sie zei- NOTE: The LEDs for the valves, pressure switches, and
gen würde, wenn der Timer für die Filterwartung abgelau- desiccant towers are not used for service indication.
fen wäre.
• Der Trockner setzt die normale Zyklusabarbeitung fort. To extinguish the service LED and clear the service message
Anmerkung: Die LEDs für die Ventile, Druckschalter und from the text display, go to Program Mode and reset the appropriate
Trockenmittelbehälter werden nicht zur Alarmanzeige be- service timer. If a filter monitor is installed, reset the monitor to
nutzt. clear the Service LED.
The following text display is shown for each service message.
Um die Service-LED und die Servicemitteilung vom Display zu Replacement or repair of the affected item may or may not be
löschen, zum Programmodus gehen und den jeweiligen necessary. The service reminders are used to schedule routine
Servicetimer zurücksetzen. Ist eine Filterüberwachung instal- evaluation of the operational status of key components.
liert, das Überwachungsgerät zurücksetzen, um die Service-
LED zu löschen.
Der folgende Text wird für jede Servicemitteilung angezeigt.

9.7.2.1 Servicemodus Screen 1 – Service Filter 9.7.2.1 Service Mode Screen 1 – Service filters
SERVICE TROCKNER SERVICE DRYER
_______________________________________ _______________________________________

FILTER FILTERS

Druckverlustmessung am Filter kontrollieren und sicherstellen, Check filter Delta-P gauges and ensure that drains are functioning
dass die Kondensatableiter ordnungsgemäß funktionieren. Das properly. Inspect pilot air filter element. Check filter monitors, if
Steuerluftfilterelement kontrollieren. Falls montiert, die Filter- equipped.
überwachungsgeräte kontrollieren.

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.7.2.2 Servicemodus Screen 2 – Service Trocken- 9.7.2.2 Service Mode Screen 2 – Service
mittel desiccant
SERVICE TOCKNER SERVICE DRYER
_______________________________________ _______________________________________

TROCKENMITTEL DESICCANT

Feuchtigkeitsanzeiger bzw. Taupunkt (Option) kontrollieren und Check moisture indicator or outlet dew point and inspect mufflers
Schalldämpfer hinsichtlich übermäßige Staubablagerungen über- for excessive dusting.
prüfen.

9.7.2.3 Servicemodus Screen 3 – Service Ventile 9.7.2.3 Service Mode Screen 3 – Service valves

SERVICE TROCKNER SERVICE DRYER

_______________________________________ _______________________________________

VENTILE VALVES

Stellen Sie sicher, dass die Ventile dem Zyklus der Steuerung Ensure that valves are cycling properly. Check for switching
ordnungsgemäß folgen. Kontrolle im Hinblick auf Schaltfehler- failure alarms and adjust purge pressure. Check for leaks.
alarme, Regenerationsluftdruck einstellen. Auf Undichtigkeiten
achten.

9.8 Displaymodus 9.8 Display Mode

• Der Displaymodus ist aktiv, wenn der Bediener den Pro- • Display Mode is active when the user exits Program Mode
gramm- oder Setupmodus verlässt (es sei denn, der MA- or Setup Mode (unless MANUAL cycle was selected in
NUELLE Zyklus wurde im Setup-Modus angewählt) und Setup Mode) and no alarms are active.
keine Alarme aktiv sind.
• Display Mode is comprised of several screens (described
• Der Displaymodus umfasst mehrere Screens (Beschrei- below). The controller automatically scrolls through the
bung siehe unten). Die Steuerung scrollt automatisch durch screens, displaying each one for 4 seconds. The user can
die Screens und zeigt jeden 4 Sekunden lang an. Der Bedie- override the 4 second time period and force the next screen
ner kann den 4-Sekunden-Zeitraum überspringen, indem er
to be displayed by pressing .
drückt.
• The screens are displayed in the following sequence: 1, 2,
• Die Screens werden in folgender Abfolge angezeigt: 1, 2, 3A, 4, 5, 6, 1, 2, 3B, 4, 5, 6, 1, 2, 3C, 4, 5, 6, 1, 2, 3D, 4, 5, 6,
3A, 4, 5, 6, 1, 2, 3B, 4, 5, 6, 1, 2, 3C, 4, 5, 6, 1, 2, 3D, 4, 5, 6 … with the exceptions noted below.
… wobei die unten angegebenen Ausnahmen gelten.

9.8.1 Displaymodus Screen 1 – Taupunktklasse und 9.8.1 Display Mode Screen 1 – Dew point class and
Zyklustyp cycle type.
2: -40°C/-40°F 2: -40°C/-40°F
_______________________________________ _______________________________________

BELADUNGSABH. DEMAND CYCLE

9.8.2 Displaymodus Screen 2 – Energiesparen 9.8.2 Display Mode Screen 2 – Energy savings.
Dieses Screen wird nicht angezeig, wenn der FESTE ZYKLUS This screen is not displayed if FIXED cycle is selected.
angewählt wird.

ENERGIEERSPARNIS ENERGY SAVINGS

_______________________________________ _______________________________________

XX% XX%

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.8.3 Displaymodus Screen 3A – Service- 9.8.3 Display Mode Screen 3A – Service reminder
erinnerung (Filter) (filters)
Dieses Screen wird nicht angezeigt, wenn 1 oder 2 Filtermonitore This screen is not displayed if 1 or 2 filter monitors are detected.
aufgefunden werden.

STD. BIS SERVICE HOURS TO SERVICE

_______________________________________ _______________________________________

FILTER: XXXX FILTERS: XXXX

9.8.4 Displaymodus Screen 3B – Service- 9.8.4 Display Mode Screen 3B – Service reminder
erinnerung (Trockenmittel) (desiccant)
STD. BIS SERVICE HOURS TO SERVICE
_______________________________________ _______________________________________

TROCKENMITTEL: XXXX DESICCANT: XXXX

9.8.5 Displaymodus Screen 3C – Service- 9.8.5 Display Mode Screen 3C – Service reminder
erinnerung (Ventile) (valves)
STD. BIS SERVICE HOURS TO SERVICE
_______________________________________ _______________________________________

VENTILE: XXXX VALVES: XXXX

9.8.6 Displaymodus Screen 3D – Zähler Ventil- 9.8.6 Display Mode Screen 3D – Valve cycle
zyklus counter
ZYKLUSZÄHLER ZYKLUSZÄHLER
_______________________________________ _______________________________________

XXXXXXX XXXXXXX

9.8.7 Displaymodus Screen 4 – Taupunkt Trockner- 9.8.7 Display Mode Screen 4 – Dryer outlet dew
ausgang (AUX2, Analogeingang) point,(AUX2, analog input)
Dieses Screen wird nicht angezeigt, wenn Jumper 3 nicht instal- This screen is not displayed if jumper 3 is not installed.
liert wird.

TP. AM AUSTRITT OUTLET DEW POINT

_______________________________________ _______________________________________

+XX°C +XXX°F +XX°C +XXX°F

9.8.8 Displaymodus Screen 5 – Eintrittsdruck 9.8.8 Display Mode Screen 5 – Dryer inlet
Trockner (AUX3, Analogeingang) pressure, (AUX3, analog input)
Dieses Screen wird nicht angezeigt, wenn Jumper 4 nicht instal- This screen is not displayed if jumper 4 is not installed.
liert wird.

EINTRITTSDRUCK INLET PRESSURE

_______________________________________ _______________________________________

XX BARG XXX PSIG XX BARG XXX PSIG

9.8.9 Displaymodus Screen 6 – Eintrittstemperatur 9.8.9 Display Mode Screen 6 – Dryer inlet
Trockner (AUX3, Analogeingang) temperature, (AUX3, analog input)
Dieses Screen wird nicht angezeigt, wenn Jumper 5 nicht instal- This screen is not displayed if jumper 5 is not installed.
liert wird.

EINTRITTSTEMP. INLET TEMP.

_______________________________________ _______________________________________

XX°C XXX°F XX°C XXX°F

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.9 Testmodus 9.9 Test Mode

• Der Testmodus ist aktiv, wenn der Bediener den Setup- • Test Mode is active when the user exits Setup Mode after
Modus nach der Anwahl im MANUELLEN ZYKLUS verlässt. selecting operation in MANUAL CYCLE.
• Der Testmodus umfasst acht Screens (siehe Tabelle 9-2). • Test Mode is comprised of eight screens (descriptions follow
Jedes Screen entspricht einem der acht Programmschritte the table below). Each screen corresponds to one of eight
program steps (described in the table 9-2).
• Taste drücken, um von einem Screen (Programm-
• Press to advance from one screen (program step) to
schritt) zum nächsten zu kommen. Sicherstellen, dass alle
Vorsichtsmaßnahmen, die in den Screenbeschreibungen the next. Be sure to read and understand all cautions listed
(Programmschritten) aufgeführt sind, gelesen und verstan- with the screen (program step) descriptions.
den werden. • If the temperature is below +4°C or the thermistor circuit is
• Liegt die Temperatur unter +4°C oder ist der Thermosen- open, the second line of the display will read ”UNDER-RAN-
sorkreis offen, erscheint in der zweiten Zeile des Display GE” instead of the temperature reading. (Refer to screens
“UNTER MITTELWERT” anstelle der Temperaturanzeige (vgl. 2, 3, 4, 6, 7, and 8.)
Screens 2, 3, 4, 6, 7 und 8). • If the temperature is above +66°C or the thermistor circuit is
• Ist die Temperatur oberhalb +66°C oder der Thermosensor shorted, the second line of the display will read ”OVER-
ist kurzgeschlossen, erscheint in der 2. Zeile des Displays RANGE” instead of the temperature reading. (Refer to
„ÜBER MITTELWERT“ anstelle der Temperaturanzeige (sie- screens 2, 3, 4, 6, 7, and 8.)
he auch Screens 2, 3, 4, 6, 7 und 8). • Upon entering Test Mode, the program can be at any one of
• Bei Eintritt in den Testmodus kann das Programm an einem the eight steps.
der acht Schritte sein. • To exit Test Mode:
• Zum Verlassen des Testmodus:
1. Use to manually advance the program to step 1 or
1. Taste drücken, um von Hand im Programm auf
5.
Schritt 1 oder 6 zu gehen. a) The program must be set at step 1 or 5 to exit Test
a) Das Programm muss bei Schritt 1 oder 5 eingestellt Mode.
sein, um den Testmodus zu verlassen. b) Screen 9 is displayed for 3 seconds if the user attempts
b) Screen 9 wird 3 Sekunden lang angezeigt, falls der to exit the program from step 2, 3, or 4.
Bediener versucht, das Programm von den Schritten 2, c) Screen 10 is displayed for 3 seconds if the user
3 oder 4 zu verlassen. attempts to exit the program from step 6, 7, or 8.
c) Screen 10 wird 3 Sekunden lang angezeigt, falls der
Bediener versucht, das Programm von den Schritten 6, 2. Press and hold for 3 seconds to exit Test Mode.
7 oder 8 zu verlassen
The display switches to Screen 2 of Setup Mode.
2. Taste 3 Sekunden lang drücken und halten, um
3. Use to select DEMAND CYCLE or FIXED CYCLE.
den Testmodus zu verlassen. Die Anzeige schaltet auf
Screen 2 des Testmodus. 4. Press to accept the selection and activate Display
3. Taste drücken, um BELADUNGSABHÄNGIGER- Mode.
ZYKLUS oder den FESTEN ZYKLUS anzuwählen.

4. Taste drücken, und die Anwahl zu bestätigen und

den Displaymodus zu aktivieren.

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 Programmschritt
1 2 3 4 5 6 7 8
Program Step

Status linker Behälter trocknet trocknet trocknet trocknet regeneriert regeneriert regeneriert regeneriert
Left tower status drying drying drying drying regenerating regenerating regenerating regenerating

Status rechter Behälter regeneriert regeneriert regeneriert regeneriert trocknet trocknet trocknet trocknet
Right tower status regenerating regenerating regenerating regenerating drying drying drying drying

Kontakt geschlossen bei Start, Kontakt geöffnet bei Start,

Druckschalter linker Behälter geschlossen geschlossen geschlossen geschlossen geschlossen geschlossen Kontakt geöffnet bei Ende Kontakt geschlossen bei Ende
Left tower pressure switch closed closed closed closed closed closed closed at start, open at start,
open at end closed at end

Kontakt geschlossen bei Start, Kontakt geöffnet bei Start,

Druckschalter rechter Behälter geschlossen geschlossen Kontakt geöffnet bei Ende Kontakt geschlossen bei Ende geschlossen geschlossen geschlossen geschlossen
Right tower pressure switch closed closed closed at start, open at start, closed closed closed closed
Tabelle 9-2

open at end closed at end

Magnetventil Eintritt links aus aus aus aus aus ein ein ein
Left inlet solenoid off off off off off on on on
Schritte der Zyklusabfolge

Magnetventil Regeneration links aus aus aus aus aus aus ein aus
Left purge solenoid off off off off off off on off

Magnetventil Eintritt rechts aus ein ein ein aus aus aus aus
Right inlet solenoid off on on on off off off off

Magnetventil Regeneration rechts aus aus ein aus aus aus aus aus
9. Steuerung (ECO-CONTROL)

Right purge solenoid off off on off off off off off

Eintrittsventil links geöffnet geöffnet geöffnet geöffnet geöffnet geschlossen geschlossen geschlossen
Left inlet valve open open open open open closed closed closed

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Regenerationsventil links geschlossen geschlossen geschlossen geschlossen geschlossen geschlossen geöffnet geschlossen
Left purge valve closed closed closed closed closed closed open closed

Eintrittsventil rechts geöffnet geschlossen geschlossen geschlossen geöffnet geöffnet geöffnet geöffnet
Right inlet valve open closed closed closed open open open open

Regenerationsventil rechts geschlossen geschlossen geöffnet geschlossen geschlossen geschlossen geschlossen geschlossen
Right purge valve closed closed open closed closed closed closed closed

Temperaturanzeige-Fühlerposition keine oben links unten rechts oben links keine oben rechts unten links oben rechts
Temperature display-thermistor location none upper left lower right upper left none upper right lower left upper right

A3237

D-Name
erstellt
07.03.07 SK

Name
Table 9-2

gepr.
Cycle Sequence Steps

07.03.07 KC

Name
A2826
9. Control (ECO-CONTROL)

ersetzt f. ersetzt d.
 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.9.1 Testmodus Screen 1 – Schritt 1 9.9.1 Test Mode Screen 1 – Step 1

TESTMOD. SCHRITT 1 TEST MODE STEP 1
_______________________________________ _______________________________________

OK ZUM BEENDEN OK TO EXIT NOW

• Keine Temperaturanzeige in diesem Screen. • No temperature display on this screen.

• Taste drücken, um zu Screen 2 zu gelangen. • Press to advance to screen 2.

9.9.2 Test Mode Screen 2 – Step 2

9.9.2 Testmodus Screen 2 – Schritt 2
TEST MODE STEP 2
_______________________________________
TESTMOD. SCHRITT 2
_______________________________________ XX°C XXX°F
XX°C XXX°F
• The left tower drying light is blinking to indicate the thermistor
• Die LED für “linker Behälter trocknet” blinkt (oben links), um location (upper left) that corresponds to the temperature
anzuzeigen, welche Temperatur im Display zu sehen ist. display.

• Taste drücken, um zu Screen 3 zu gelangen. • Press to advance to screen 3.

9.9.3 Testmodus Screen 3 – Schritt 3 9.9.3 Test Mode Screen 3 – Step 3

TESTMOD. SCHRITT 3 TEST MODE STEP 3
_______________________________________ _______________________________________

XX°C XXX°F XX°C XXX°F

• Die LED für “rechter Behälter regeneriert” blinkt (unten • The right tower regenerating light is blinking to indicate the
rechts), um anzuzeigen, welche Temperatur im Display zu thermistor location (lower right) that corresponds to the
sehen ist. temperature display.

• Taste drücken, um zu Screen 4 zu gelangen. • Press to advance to screen 4.

9.9.4 Testmodus Screen 4 – Schritt 4 9.9.4 Test Mode Screen 4 – Step 4

TESTMOD. SCHRITT 4 TEST MODE STEP 4
_______________________________________ _______________________________________

XX°C XXX°F XX°C XXX°F

• LED für “linker Behälter trocknet” blinkt (oben links), um an- • The left tower drying light is blinking to indicate the thermistor
zuzeigen, welche Temperatur im Display zu sehen ist. location (upper left) that corresponds to the temperature
• Vorsicht: Nicht zu Schritt 5 weiterschalten, bis der display.
rechte Behälter vollständig unter Betriebsdruck • Caution: Do not advance to step 5 until the right tower has
steht. fully pressurized.

• Taste drücken, um zu Screen 5 zu gelangen. • Press to advance to screen 5.

9.9.5 Testmodus Screen 5 – Schritt 5 9.9.5 Test Mode Screen 5 – Step 5

TESTMOD. SCHRITT 5 TEST MODE STEP 5
_______________________________________ _______________________________________

OK ZUM BEENDEN OK TO EXIT NOW

• Keine Temperaturanzeige in diesem Screen. • No temperature display on this screen.

• Taste drücken, um zu Screen 6 zu gelangen. • Press to advance to screen 6.

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.9.6 Testmodus Screen 6 – Schritt 6 9.9.6 Test Mode Screen 6 – Step 6

TESTMOD. SCHRITT 6 TEST MODE STEP 6
_______________________________________ _______________________________________

XX°C XXX°F XX°C XXX°F

• LED für “rechter Behälter trocknet” blinkt (oben rechts), um • The right tower drying light is blinking to indicate the thermistor
anzuzeigen, welche Temperatur im Display zu sehen ist. location (upper right) that corresponds to the temperature
display.
• Taste drücken, um zu Screen 7 zu gelangen.
• Press to advance to screen 7.

9.9.7 Testmodus Screen 7 – Schritt 7 9.9.7 Test Mode Screen 7 – Step 7

TESTMOD. SCHRITT 7 TEST MODE STEP 7
_______________________________________ _______________________________________

XX°C XXX°F XX°C XXX°F

• LED für „linker Behälter regeneriert“ blinkt (unten links), um • The left tower regenerating light is blinking to indicate the
anzuzeigen welche Temperatur im Display zu sehen ist. thermistor location (lower left) that corresponds to the
temperature display.
• Taste drücken, um zu Screen 8 zu gelangen.
• Press to advance to screen 8.

9.9.8 Testmodus Screen 8 – Schritt 8 9.9.8 Test Mode Screen 8 – Step 8

TESTMOD. SCHRITT 8 TEST MODE STEP 8
_______________________________________ _______________________________________

XX°C XXX°F XX°C XXX°F

• Die LED „rechter Behälter trocknet“ blinkt, um die Lage des • The right tower drying light is blinking to indicate the thermistor
Thermosensors anzuzeigen, (oben rechts) dessen Tempe- location (upper right) that corresponds to the temperature
ratur gerade auf dem Display erscheint. display.
• Vorsicht: Nicht zu Schritt 1 weiterschalten, bevor der linke • Caution: Do not advance to step 1 until the left tower has
Behälter nicht wieder unter Betriebsdruck erscheint. fully pressurized.

• Taste drücken, um zu Schritt 1 zu gelangen. • Press to advance to screen 1.

9.9.9 Testmodus Screen 9 – Test modus verlas- 9.9.9 Test Mode Screen 9 – Attempting to exit test
sen aus Schritt 2, 3 oder 4 mode from step 2, 3, or 4
TEST BEENDEN TO EXIT TEST
_______________________________________ _______________________________________

GEHE ZU SCHRITT 5 GO TO STEP 5

• Dieser Screen wird für 5 Sekunden angezeigt, wenn der • This screen is displayed for 5 seconds if the user attempts
Testmodus aus Schritt 2, 3 oder 4 verlassen wird. to exit test mode from step 2, 3, or 4.
• Nach Ende der 5 Sekunden, kehrt das Display zu vorheri_ • At the end of the 5-second time period, the display returns
gem Screen (2, 3 oder 4) zurück. to the previous screen (2, 3, or 4).

9.9.10 Testmodus Screen 10 – Test modus verlas- 9.9.10 Test Mode Screen 10 – Attempting to exit
sen aus Schritt 6, 7 oder 8 test mode from step 6, 7, or 8.
TEST BEENDEN TO EXIT TEST
_______________________________________ _______________________________________

GEHE ZU SCHRITT 1 GO TO STEP 1

• Dieser Screen wird für 5 Sekunden angezeigt, wenn der • This screen is displayed for 5 seconds if the user attempts
Testmodus aus Schritt 6, 7 oder 8 verlassen wird. to exit test mode from step 6, 7, or 8.
• Nach Ende der 5 Sekunden, kehrt das Display zu vorheri_ • At the end of the 5-second time period, the display returns
gem Screen (6, 7 oder 8) zurück. to the previous screen (6, 7, or 8).
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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.10 Zeiten der festen Zykluszeiten 9.10 Fixed Cycle timing

Max. Betriebsdruck Trockner 5 - 10 bar 9 - 16 bar

Max. operating pressure dryer 60-150 psig 120-232 psig
ISO Klasse
1 2 3 4 1 2 3 4
ISO Class
Taupunkt -70°C -40°C -20°C +3°C -70°C -40°C -20°C +3°C
Dew Point -94°F -40°F -4°F +38°F -94°F -40°F -4°F +38°F
Zykluszeit (Minuten)
4 10 16 24 4 10 16 24
Cycle Time (minutes)
Zeit Zeit nach dem Start des Zyklus (Minuten: Sekunden Zeit nach dem Start des Zyklus (Minuten: Sekunden
Time Time from start of cycle (minutes : seconds) Time from start of cycle (minutes : seconds)
t0 00:00 00:00 00:00 00:00 00:00 00:00 00:00 00:00
t1 00:02 00:02 00:02 00:02 00:02 00:02 00:02 00:02
t2 00:06 00:06 00:06 00:06 00:06 00:06 00:06 00:06
t3 01:12 04:00 06:55 10:50 00:48 03:00 05:40 09:20
t4 02:00 05:00 08:00 12:00 02:00 05:00 08:00 12:00
t5 02:02 05:02 08:02 12:02 02:02 05:02 08:02 12:02
t6 02:06 05:06 08:06 12:06 02:06 05:06 08:06 12:06
t7 03:12 09:00 14:55 22:50 02:48 08:00 13:40 21:20
t8 04:00 10:00 16:00 24:00 04:00 10:00 16:00 24:00
Referenz Daten / Reference Data
Regenerationszeit (min:sek)
[(t3-t2) oder (t7-t6)]
01:06 03:54 06:49 10:44 00:42 02:54 05:34 09:14
Purge time (min:sec)
[(t3-t2) or (t7-t6)]
Druckaufbauzeit (min:sek)
[(t4-t3) oder (t8-t7)]
00:48 01:00 01:05 01:10 01:12 02:00 02:20 02:40
Repress. time (min:sec)
[(t4-t3) or (t8-t7)]

Bemerkung: Während des Betriebes im „Beladungs- NOTE: When operated in the Demand Mode, drying times
abhängigen Zyklus“ können die Trockenzeiten t4-t0 and t8-t4 can extend to a maximum of 30 minutes
t4 - t0 und t8 - t4 auf jeweils 30 Minuten erweitert werden. each. Purge times in the Demand Mode, regardless of
Die Regenerationszeiten im „Beladungsabhängigen Zy- the ISO Class selection, will always be equal to the purge
klus“ unabhängig von der ISO-Klassen-Anwahl, wird im- times of the ISO Class 2 (10 min.) Fixed Cycle 3:54.
mer gleich der Regenerationszeit der ISO-Klasse 2 (10
Min.) sein. Fester Zyklus 3:54

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.11 Zeitlicher Ablauf des Bauteilestatus 9.11 Event Sequence and Component Status

Zeit (bezogen auf Tabelle Kap. 9.10) / Time (refer to Table chapter 9.10)
Bauteilebezeichnung t0 t1 t2 t3 t4 t5 t6 t7 t8
(stromloser Zustand) Linker Behälter trocknet Rechter Behälter trocknet
Process valve name Rechter Behälter regeneriert Linker Behälter regeneriert
(Process valve state w/ de-energized Halber Zyklus Halber Zyklus
pilot solenoid valve) Left Tower Drying Right Tower Drying
Right Tower Regenerating Left Tower Regenerating
Half Cycle Half Cycle
Ventil
Regenerationsventil links
angesteuert
(stromlos geschlossen)
(geöffnet)
Left purge valve
Pilot energized
(normally closed)
(open)
Eintrittsventil links
(stromlos geöffnet) Ventil angesteuert (geschlossen)
Left inlet valve Pilot Energized (closed)
(normally open)
Eintrittsventil rechts
(stromlos geöffnet) Ventil angesteuert (geschlossen)
Right inlet valve Pilot energized (closed)
(normally open)
Regenerationsventil rechts Ventil angesteuert
(stromlos geschlossen) (geöffnet)
Right purge valve Pilot energized
(normally open) (open)
Druckschalterzustand / Normal status of pressure switches
Druckschalter geschlossen für < 5 an t7 geöffnet,
Linker Behälter Geschlossen Geschlossen Geschlossen Geschlossen Geschlossen Geschlossen sek. dann offen vor t8 geschlossen
Left tower closed closed closed closed closed closed closed for < 5 sec. open at t7, closed
Pressure switch Then open before t8
Druckschalter geschlossen für < 5 an t3 geöffnet,
Rechter Behälter Geschlossen Geschlossen sek. dann offen vor t4 geschlossen Geschlossen Geschlossen Geschlossen Geschlossen
Right tower closed closed closed for < 5 sec. open at t3, closed closed closed closed closed
Pressure switch Then open before t4

Druckschalterzustand der einen Alarm auslöst / Pressure switch status that causes an alarm
Linker Behälter trocknet
a 1 1
Behälter Druck min. offen offen
Left tower drying open open
a
Low tower pressure
Linker Behälter regeneriert
b 1
Fehler beim Entlasten geschlossen
Left tower regenerating closed
b
Fail to de-pressurize
Linker Behälter regeneriert
c 2
Fehler beim Druckaufbau offen
Left tower regenerating open
c
Fail to re-pressurize
Rechter Behälter trocknet
d 1 1
Behälter Druck min. offen offen
Right tower drying open open
d
Low tower pressure
Rechter Behälter regeneriert
e 1
Fehler beim Entlasten geschlossen
Right tower regenerating closed
e
Fail to de-pressurize
Rechter Behälter regeneriert
f 2
Fehler beim Druckaufbau offen
Right tower regenerating open
f
Fail to re-pressurize
Zyklus-Stop
bei Störung ?
Note: Bemerkungen / Comments
Stop cycle on
fault?
1: Auf Störung überprüfen bei 15,
Wenn die Störung für einen Zyklus nicht mehr auftritt: bleibt die Alarm LED (ohne zu blinken) an und die Störung wird im
25, 35,... Sekunden innerhalb des
Nein Display angezeigt. Sobald die Störung beseitigt ist, RESET-Taster zum quittieren der Anzeige und der LED betätigen.
halben Zyklus
No If the fault condition is clear for 1 cycle: the alarm LED stays on (without blinking) and the alarm message continues to be
Check for fault condition at 15, 25,
displayed. Once the fault condition is clear, pressing the reset button will clear the alarm LED and message.
35 ... seconds into the half cycle
2: Auf Störung überprüfen, bevor Ist die Störung beseitigt: arbeitet der Adsorber im Zyklus weiter und die Alarm LED bleibt (ohne zu blinken) an.
der halbe Zyklus endet Ja Sobald die Störung beseitigt ist, RESET-Taster zum quittieren der Anzeige und der LED betätigen.
Check for fault condition just before Yes If the fault condition clears: tower cycling resumes and the the alarm LED stays on (without blinking. Once the fault
the end of the half-cycle condition is clear, pressing the reset button will clear the alarm LED and message.
a: Alarm LED blinkt und Displayanzeige: Alarm + linker Behälter trocknet + Druck min.
a: Blink the Alarm LED and display the following text message: alarm + left tower drying + low pressure
b: Alarm LED blinkt und Displayanzeige: Alarm + linker Behälter regeneriert + Druck max.
b: Blink the Alarm LED and display the following text message: alarm + left tower regenerating + high pressure
c: Alarm LED blinkt und Displayanzeige: Alarm + linker Behälter regeneriert + Druck min.
c: Blink the Alarm LED and display the following text message: alarm + left tower regenerating + low pressure
d: Alarm LED blinkt und Displayanzeige: Alarm + rechter Behälter trocknet + Druck min.
d: Blink the Alarm LED and display the following text message: alarm + right tower drying + low pressure
e: Alarm LED blinkt und Displayanzeige: Alarm + rechter Behälter regeneriert + Druck max.
e: Blink the Alarm LED and display the following text message: alarm + right tower regenerating + high pressure
f: Alarm LED blinkt und Displayanzeige: Alarm + rechter Behälter regeneriert + Druck min.
f: Blink the Alarm LED and display the following text message: alarm + right tower regenerating + low pressure

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 9. Steuerung (ECO-CONTROL) 9. Control (ECO-CONTROL)

9.12 Panel Layout 9.12 Panel Layouts

1 11
12
2
p1 p2
3 13

p3
4
14
5

6 15

7 16

8 17
9 18

19

20
10

1. LED Druckschalter linker Behälter 1. Left tower pressure switch LED:

Ein= Kontakt geschlossen; Aus= Kontakt geöffnet On= switch closed; Off= switch open
2. LED linker Behälter trocknet 2. Left tower drying LED
3. LED Regenerationsventil links 3. Left purge valve LED:
Ein= Ventil offen; Aus= Ventil geschlossen On= valve open; Off= valve closed
4. LED Eintrittsventil links 4. Left inlet valve LED:
Ein= Ventil offen; Aus= Ventil geschlossen On= valve open; Off= valve closed
5. LED linker Behälter regeneriert 5. Left tower regenerating LED
6. LED Service/ Wartung Filter 6. Filter service/ maintenance LED
7. Textdisplay 7. Text display
8. Wahlschalter Betriebsmodus 8. Operating mode selector switch
9. LED Spannung Ein 9. Power On LED
10. Ein/Aus-Schalter 10. Power On/ Off switch
11. LED Service/ Wartung Filter 11. Filter service/ maintenance LED
12. LED Druckschalter rechter Behälter 12. Right tower pressure switch LED:
Ein= Kontakt geschlossen; Aus= Kontakt geöffnet On= switch closed; Off= switch open
13. LED rechter Behälter trocknet 13. Right tower drying LED
14. LED Regenerationsventil rechts 14. Right purge valve LED:
Ein= Ventil offen; Aus= Ventil geschlossen On= valve open; Off= valve closed
15. LED rechter Behälter regeneriert 15. Right tower regenerating LED
16. LED Eintrittsventil rechts 16. Right inlet valve LED:
Ein= Ventil offen; Aus= Ventil geschlossen On= valve open; Off= valve closed
17. ENTER-TAste 17. Enter switch
18. LED Service-/Wartungs-Erinnerung 18. Maintenance/ service reminder LED
19. LED Alarm 19. Alarm LED
20. RESET-Taster zum quittieren bei Alarm und Wartungserin- 20. Reset switch for alarm and maintenance reminder
nerungen. 21. Pressure gauge left tower
21. Manometer linker Behälter 22. Pressure gauge right tower
22. Manometer rechter Behälter 23. Pressure gauge orifice pre-pressure
23. Manometer Blendenvordruck 24. Filter monitor pre-filter
24. Filtermonitor-Vorfilter 25. Filter monitor after-filter
25. Filtermonitor-Nachfilter

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 9. Steuerung (ECO CONTROL) 9. Control (ECO CONTROL)

9.13 Programmschritte im manuellen 9.13 Steps in the manual mode

Bereich

1. Schritt: 1. Step:
V003 (Eintritt links) und V002 (Eintritt rechts) sind geöffnet. V003 (Inlet left) and V002 (Inlet right) are open.
(Behälter links trocknet) PS029 (Druckschalter links) und PS028 (Tower left is drying) PS029 (Pressure switch left) and PS028
(Druckschalter rechts) sind geschlossen. Entspricht dem Zu- (Pressure switch right) are closed. Is equivalent to the status
stand zwischen t0 und t1. (Tabellen: 9.10, 9.11) between t0 and t1. (Table: 9.10, 9.11)

2. Schritt: 2. Step:
V002 (Eintritt rechts) schließt. V002 (Inlet right) closed.
PS029 (Druckschalter links) und PS028 (Druckschalter rechts) PS029 (Pressure switch left) and PS028 (Pressure switch
sind geschlossen. Entspricht dem Zustand zwischen t1 und right) are closed. Is equivalent to the status between t1 and t2.
t2. (Tabellen: 9.10, 9.11) (Table: 9.10, 9.11)

3. Schritt: 3. Step:
V015 (Regenerationsaustritt rechts) öffnet. V015 (Purge outlet right) opened.
PS029 (Druckschalter links) ist geschlossen, PS028 (Druck- PS029 (Pressure switch left) is closed, PS028 (Pressure
schalter rechts) öffnet innerhalb von 5 Sekunden. Entspricht switch right) opened at the time of 5 Seconds. Is equivalent to
dem Zustand zwischen t2 und t3. (Tabellen: 9.10, 9.11) the status between t2 and t3. (Table: 9.10, 9.11)

4. Schritt: 4. Step:
V015 (Regenerationsaustritt rechts) schließt. V015 (Purge outlet right) closed.
PS029 (Druckschalter links) ist geschlossen, PS028 (Druck- PS029 (Pressure switch left) is closed, PS028 (Pressure
schalter rechts) schließt bevor t4 erreicht ist. Entspricht dem switch right) closed until t4 reached is. Is equivalent to the
Zustand zwischen t3 und t4. (Tabellen: 9.10, 9.11) status between t3 and t4. (Table: 9.10, 9.11)

5. Schritt: 5. Step:
V003 (Eintritt links) und V002 (Eintritt rechts) sind geöffnet. V003 (Inlet left) and V002 (Inlet right) are open. (Tower right is
(Behälter rechts trocknet) PS029 (Druckschalter links) und drying) PS029 (Pressure switch left) and PS028 (Pressure
PS028 (Druckschalter rechts) sind geschlossen. Entspricht switch right) are closed. Is equivalent to the status between
dem Zustand zwischen t4 und t5. (Tabellen: 9.10, 9.11) t4 and t5. (Table: 9.10, 9.11)

6. Schritt: 6. Step:
V003 (Eintritt links) schließt. V003 (Inlet left) closed.
PS029 (Druckschalter links) und PS028 (Druckschalter rechts) PS029 (Pressure switch left) and PS028 (Pressure switch
sind geschlossen. Entspricht dem Zustand zwischen t5 und right) are closed. Is equivalent to the status between t5 and t6.
t6. (Tabellen: 9.10, 9.11) (Table: 9.10, 9.11)

7. Schritt: 7. Step:
V014 (Regenerationsaustritt links) öffnet. V014 (Purge outlet left) opened.
PS028 (Druckschalter rechts) ist geschlossen, PS029 (Druck- PS028 (Pressure switch right) is closed, PS029 (Pressure
schalter links) öffnet innerhalb von 5 Sekunden. Entspricht switch left) opened at the time of 5 Seconds. Is equivalent to
dem Zustand zwischen t6 und t7. (Tabellen: 9.10, 9.11) the status between t6 and t7. (Table: 9.10, 9.11)

8. Schritt: 8. Step:
V014 (Regenerationsaustritt links) schließt. V014 (Purge outlet left) closed.
PS028 (Druckschalter rechts) ist geschlossen, PS029 (Druck- PS028 (Pressure switch right) is closed, PS029 (Pressure
schalter links) schließt bevor t8 erreicht ist. Entspricht dem switch left) closed until t8 reached is. Is equivalent to the
Zustand zwischen t7 und t8. (Tabellen: 9.10, 9.11) status between t7 and t8. (Table: 9.10, 9.11)

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 10. Funktionsbeschreibung 10. Description of operation

Kaltregenerierende Adsorptionstrockner nutzen die natürliche Heatless-regenerating desiccant dryers utilise the natural
Tendenz des Trockenmittels ein Gleichgewicht des Wasserdampf- tendency of the desiccant to establish a balance from the water
partialdruckes mit der umgebenden Luft zu erreichen. vapor partial pressure with the ambient air.
Während des Trockenvorgangs adsorbiert das Trockenmittel den In the course of the drying process, the desiccant adsorbs water
Wasserdampf von der eintretenden Druckluft. Ein Teilstrom ge- vapour from the incoming compressed air. Part of the incoming
trockneter, im Druck reduzierter Druckluft wird anschließend über flow of compressed air, which has been dried and reduced in
das Trockenmittel geführt. Dabei gibt das Trockenmittel die auf- pressure, is then passed over the desiccant. It discharges the
genommene Feuchtigkeit an die durchströmende Regenerations- previously adsorbed water to the purge air.
luft ab.
Remark!
HINWEIS The component specified in parentheses (e.g. B006)
Die in Klammern näher bezeichneten Bauteile (z.B. refer to the R&I schematic diagram.
B006) beziehen sich auf das R&I-Schema.

10.1 Wirkungsweise 10.1 Operation

• Die eintretende Druckluft wird durch die Drucklufteintritts- • The incoming compressed air passes through inlet air
armatur (V003) über den Strömungsverteiler zum linken valve (V003) via flow distributor to desiccant tower
Adsorptionsmittelbehälter (B007) geleitet und hier durch (B007), where it is dried by the desiccant. (t0 ® t4)
das Adsorptionsmittel getrocknet. (t0 ® t4)
• The compressed air then flows through the flow
• Anschließend strömt die trockene Druckluft durch den distributor and the shuttle valve (V013) to the compressed
Strömungsverteiler am oberen Behälterende und durch air outlet. (t0 ® t4)
das Wechselventil (V013) zum Druckluftausgang.
(t0 ® t4) • A portion of the dried air flows through the regulating
valve (V034) (adjust the pre-pressure), through the
• Gleichzeitig fließt ein Teilstrom der getrockneten Druck- orifices (X012, X013), where the dried air expands, via
luft durch die Regulierarmatur (V034) (Einstellung des flow distributor of the tower (B006) into the right tower.
Vordrucks) , durch die Drosselblenden (X012, X013), wo (t0 ® t4)
der Teilstrom im Druck entspannt wird, über die
Strömungsverteiler am oberen Ende des Adsorptions- • Here, the water vapour adsorbed during the drying
mittelbehälters (B006) in den rechten Behälter. (t0 ® t4) process is extracted from the desiccant. (t0 ® t3)

• Dort wird dem Adsorptionsmittel der Wasserdampf ent- • The wet purge air is passed through flow distributor,
zogen, den es beim vorherigen Trocknungszyklus auf- purge air valve (V015) and purge air muffler (F017) into
genommen hat. (t0 ® t3) the atmosphere. (t2 ® t3)

• Die mit Feuchtigkeit gesättigte Regenerationsluft strömt • The dryer operates according to this sequence for 4
durch den unteren Strömungsverteiler des rechten Be- minutes, after which purge air valve (V015) from the
hälter, die Regenerationsluftarmatur (V015) und den Aus- right tower closes. (t0 ® t3)
trittsschalldämpfer (F017) ins Freie. (t2 ® t3)
• The system pressure is built up in the right tower (B006).
• In dieser Anordnung arbeitet der Trockner 4 Minuten. (t3 ® t4)
Dann schließt die Regenerationsluftarmatur (V015) des
rechten Behälters. (t0 ® t3) • After 60 seconds the inlet air valve (V002) from the right
tower opens and the inlet air valve (V003) from the left
• Im rechten Behälter (B006) wir der Systemdruck aufge- tower closes. The desiccant dryer dries at the regenerated
baut. (t3 ® t4) right tower (B006). (t4 ® t5)

• Nach 60 Sekunden öffnet die Drucklufteintrittsarmatur • The purge air valve (V014) from the left tower (B007) is
(V002) des rechten Behälters und die Drucklufteintritts- opened and the tower is exhausted. (t6 ® t7)
armatur (V003) des linken Behälter schließt. Der
Adsorptionstrockner trocknet über den regenerierten rech- • The wet compressed air flows through inlet air valve
ten Behälter (B006). (t4 ® t5) (V002) and flow distributor into tower (B006), where it is
dried. (t4 ® t8)
• Die Regenerationsluftarmatur (V014) des linken Behäl-
ters (B007) öffnet. Der Behälter wird entlastet. (t6 ® t7) • Then flows the dried compressed air through flow
distributor and shuttle valve (V013) from the right tower
• Die feuchte Druckluft strömt durch die Drucklufteintritts- to the compressed air outlet. (t4 ® t8)
armatur (V002) und Strömungsverteiler in den Behälter
(B006) und wird getrocknet. (t4 ® t8)

• Anschließend wird die getrocknete Druckluft über den

Strömungsverteiler am oberen Ende des rechten Behäl-
ters über das Wechselventil (V013) zum Druckluftaustritt
geleitet. (t4 ® t8)

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 10. Funktionsbeschreibung 10. Description of operation

• Ein Teilstrom der getrockneten Druckluft wird über die • A portion of the dried air flows through the orifices (X012,
starren Blenden (X012, X013) und den Strömungsverteiler X013) and the flow distributor into the left tower (B007).
in den linken Behälter (B007) geführt. (t4 ® t8) (t4 ® t8)

• Dem Adsorptionsmittel wird die beim Trockenzyklus auf- • The water vapour which adsorbed during the drying
genommene Feuchtigkeit entzogen. (t4 ® t7) process is extracted from the desiccant. (t4 ® t7)

• Die mit Feuchtigkeit gesättigte Regenerationsluft strömt • The wet purge air is passed through flow distributor,
durch den Strömungsverteiler am unteren Ende des Be- purge air valve (V014) and purge air muffler (F016) into
hälters, die Regenerationsluftarmatur (V014) und den the atmosphere. (t6 ® t7)
Schalldämpfer (F016) ins Freie. (t6 ® t7)
• At 4 minutes again the purge air valve (V014) from the
• Nach wiederum 4 Minuten schließt die Regenerations- left tower closes. (t7)
luftarmatur (V014) des linken Behälters. (t7)
• The system pressure is built up in the regenerated tower.
• In dem regenerierten Behälter wird der Systemdruck auf- (t7 ® t8)
gebaut. (t7 ® t8)
• After 60 seconds the inlet air valve (V003) from the left
• Nach weiteren 60 Sekunden öffnet die Eintrittsarmatur tower opens and the inlet air valve (V002) from the right
(V003) des linken Behälters und die Eintrittsarmatur (V002) tower closes. (t0 ® t1)
des rechten Behälters schließt. (t0 ® t1)
• The purge air valve (V015) from the right tower opens.
• Die Regenerationsluftarmatur (V015) des rechten Behäl- (t2)
ters öffnet. (t2)
• The dryer is at the beginning from the dryer cycle again.
• Der Trockner befindet sich wieder am Beginn des
Trockenzyklus.
A complete cycle lasts 10 minutes. At this dryer cycle and in
addition with the presupposition in chapter 12. "Technical datas"
Der gesamte Trockenzyklus erstreckt sich über 10 Minuten. Bei the desiccant dryer enables the pressure dewpoint at -40°C.
diesem Trockenzyklus und den im Kapitel 12. „Technische Daten“
beschriebenen Voraussetzungen erreicht der Adsorptions-
trockner einen Drucktaupunkt von - 40°C.

10.2 ECO-CONTROL 10.2 ECO-CONTROL

ECO-CONTROL ist eine Steuerung zur Einsparung von Regen- The ECO-CONTROL represents a method of saving purge air on
erationsluft bei kaltregenerierenden Adsorptionstrocknern, die cold-regenerating desiccant dryers which are operated at part-
im Teillastbereich betrieben werden. load.
Die ECO-CONTROL - verarbeitet Temperaturänderungen im The ECO-CONTROL - processes temperature changes in the
Trockenmittelbett. desicant bed.
Diese Temperaturänderungen resultieren aus der Wärme (Ther- These temperature changes result from the heat (thermal energy)
mische Energie), die freigesetzt wird, wenn das Trockenmittel- which is released when the desiccant bed is active and drying.
bett aktiv ist und trocknet. Diese Thermische Energie wird auch These temperature means adsorption heat. The temperature
als Adsorptionswärme bezeichnet. Ferner resultiert die change result of the thermal energy, which is use to regenerated
Temperaturänderung noch aus der thermischen Energie, die be- the desiccant bed. These energy means desorption heat.
nötigt wird, um das Trockenmittelbett zu regenerieren. Diese En- The scale of the temperature changes are an indirect measure of
ergie wird auch als Desorptionswärme bezeichnet. the amount of water vapour in the compressed-air to be dried.“
Die Größe der Temperaturänderung in den Trockenmittelbehältern This information is processed by the control system, which
sind ein indirektes Maß für die Wasserdampfmenge in der zu calculated the load from the desiccant dryer and regulated the
trocknenden Druckluft. duration of the switch-over cycles when optimal use is made of
Diese Informationen verarbeitet die Steuerung und errechnet die the desiccant's thermal storage capacity. As a result, 98% and
momentane Belastung des Adsorptionstrockners und regelt an- more of the adsorption head is stored, ensuring that sufficient
hand der Parameter die Zykluszeit des Adsorptionstrockners thermal energy is available during the regeneration process to
variabel unter optimaler Ausnutzung der thermischen Speicher- guarantee the effectiveness of the purge air.
kapazität des Trockenmittels. Hierdurch werden 98% und mehr
der Adsorptionswärme gespeichert und sichergestellt, daß wäh-
rend der Regenerationsphase ausreichend thermische Energie Remark!
zu Verfügung steht um die Effektivität der Regeneration zu ge- For the connection of external trouble indication
währleisten. systems the dryer is equipped with a potential free
contact „common alarm“. For connections please
see the wiring diagram (chapter 14).
Hinweis!
Zum Anschluß externer Störmeldesysteme ist das
Gerät mit einem potentialfreien Kontakt „Sammel-
störmeldung“ ausgerüstet. Den Anschluß entneh-
men Sie bitte dem Schaltplan (siehe Kapitel 14).

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 11. Wartung und Instandhaltung 11. Servicing and maintenance

Hinweis! Remark!
Die in Klammern näher bezeichneten Bauteile (z.B. The components specified in parentheses (e.g.
B006) beziehen sich auf das R&I-Schema. B006) refer to the R&I-schematic diagram.

Warnung! Attention!
Der Adsorptionstrockner steht unter erhöhtem The desiccant dryer contains under high pressure.
Druck. Depressurize the dryer before servicing or
Vor Service- oder Reparaturarbeiten ist das Gerät repairing.
drucklos zu machen.
Remark!
Hinweis! The follow-up inspections of the adsorption dryer`s
Die Wiederholungsprüfung der Druckluftbehälter compressed-air tanks are subject to national law
des Adsorptionstrockners unterliegen dem natio- and must be carried out in accordance with the
nalstaatlichen Recht und müssen nach den im Ein- regulations applicable in the country in which the
satzland geltenden Regeln durchgeführt werden. dryre is used

11.1 Wöchentliche Wartungsarbeiten 11.1 Weekly maintenance

• Kontrolle des Restdrucks der Adsorptionsmittelbehälter • Check the residual pressure in the towers (B006 and
(B006 und B007) während der Regenerationsphase an- B007) during the regeneration with the manometer (PI018
hand der Manometer (PI018 und PI019). and PI019).

• Wird der Schaltfehleralarm durch zu hohen Restdruck • If a too high residual pressure activate the switching
ausgelöst, sind die Schalldämpfer zu ersetzen. alarm, exchange the muffler.
* Gerät ausschalten (siehe Abschnitt 4. "Ausschalten"). * Switch off the dryer (see chapter 4. "Switching off
* Schalldämpfer austauschen. the dryer").
* Gerät einschalten. * Replace the purge mufflers.
* Switch on the dryer.
• Kontrolle des Differenzdrucks vom Vor-. bzw. Nachfilter
(F001 und F012) am Filtermonitor (PdI001 bzw. PdI012), • Check the differential pressure gauge from the pre- and
siehe Bedienungsanleitung Filter. after filter (F001, F012) at filter monitor (PdI001, PdI012),
see instruction manual filter.
• Funktionskontrolle des automatischen Kondensatableiters
am Vorfilter. • Check the automatically condensate drain at the pre-filter.
* Betätigen Sie den TEST-Schalter am niveaugesteuerten * Press the TEST-button on the condensate discharger
Kondensatableiter (X001). Kondensat muß abfließen. (X001). The condensate must be discharged.

Hinweis! Remark!
Für die folgenden Wartungsarbeiten müssen die To execute the following maintenance the back
hinteren Gehäusebleche entfernt werden.. screens must be remove.

• Sichtkontrolle des Feuchtigkeitsindikators (MI021). • Visual check of the moisture indicator (MI021).
Wenn der Feuchteindikator einige Stunden mit trockener If the moisture indicator for some hours exposed dry air,
Luft in Berührung steht, besitzt er eine grüne Farbe. Bei it will get a green colour. If the relative humidity more than
einer relativen Restfeuchte von ca 5% schlägt er ins 5% the colour will changed to yellow-orange.
gelborange um. The indicator must be display a green colour, in the event
Der Feuchteindikator muß eine grüne Färbung zeigen. of a defect or overload on the dryer the colour will revert
Falls eine Störung oder Überbelastung des Trockners to yellow-orange (see chapter 5).
vorliegt wechselt die Färbung des Feuchteindikators auf
gelb-orange (siehe Kapitel 5. "Störungen").

• Kontrolle des Vordrucks an der Regenerationsluftblende • Check the pre-pressure at the purge air orifice, if
gegebenenfalls korrigieren (siehe Kapitel 8.3) necessary correct (see chapter 8.3).

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 11. Wartung und Instandhaltung 11. Servicing and maintenance

Hinweis! Remark!
Die in Klammern näher bezeichneten Bauteile (z.B. The components specified in parentheses (e.g.
B006) beziehen sich auf das R&I-Schema. B006) refer to the R&I-schematic diagram.

Warnung! Attention!
Der Adsorptionstrockner steht unter erhöhtem The desiccant dryer contains under high pressure.
Druck. Depressurize the dryer before servicing or
Vor Service- oder Reparaturarbeiten ist das Gerät repairing.
drucklos zu machen.
Remark!
Hinweis! The follow-up inspections of the adsorption dryer`s
Die Wiederholungsprüfung der Druckluftbehälter compressed-air tanks are subject to national law
des Adsorptionstrockners unterliegen dem natio- and must be carried out in accordance with the
nalstaatlichen Recht und müssen nach den im Ein- regulations applicable in the country in which the
satzland geltenden Regeln durchgeführt werden. dryre is used

11.2 Jährliche Wartungsarbeiten/ 11.2 Annual maintenance/

6000 Schraubenkompressorbetriebsstunden 6000 screw-type compressor working hours
• Filterelemente des Vor- und Nachfilters (F001 und F012) • Replace the filter cartridges from the pre- and after filter
austauschen. (F001 and F012).

* Gerät wie in Abschnitt 11.3 "Entlüftung des Adsorptions- * Unpressurized the dryer (see chapter 11.3
trockners" beschrieben entlüften. " Unpressurizing the desiccant dryer").
* Gerät ausschalten (siehe Kapitel 4. "Ausschalten"). * Switch off the dryer (see chapter 4. "Switching off the
* Austausch der Filterelemente siehe Bedienungsanleitung dryer").
Filter. * Replace the filter cartridges see instruction manual filter.

* Service unit am Kondensatableiter tauschen * Replace service unit condensate drain

Der Zusammenbau erfolgt in umgekehrter Reihenfolge. Reassembly is carried out via the reverse procedure.

* Schalldämpfer austauschen. * Replace the purge mufflers.

• Filterelement des Steuerluftfilters (PC036) austauschen. • Replace the filter cartridge from the control air filter
(PC036).

* Feuchteindikator tauschen * Replace moisture indicator

11.3 Entlüftung des Adsorptionstrockners 11.3 Unpressurize the desiccant dryer

• Schließen Sie die Absperrorgane in der Druckluftein- und • Close the shut-off devices in the compressed-air inlet-
-austrittsleitung des Trockners. and outlet line.

• Lassen Sie den Adsorptionstrockner in Betrieb. Nach • Let the desiccant dryer run. After the regeneration cycle
Ablauf eines Regenerationszyklus ist der Trockner druck- the dryer is unpressurized.
los.

• Prüfen Sie den Restdruck in den Behältern. • Check the residual pressure in the towers.

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 11. Wartung und Instandhaltung 11. Servicing and maintenance

Hinweis! Remark!
Die in Klammern näher bezeichneten Bauteile (z.B. The components specified in parentheses (e.g.
B006) beziehen sich auf das R&I-Schema. B006) refer to the R&I-schematic diagram.

Warnung! Attention!
Der Adsorptionstrockner steht unter erhöhtem The desiccant dryer contains under high pressure.
Druck. Depressurize the dryer before servicing or
Vor Service- oder Reparaturarbeiten ist das Gerät repairing.
drucklos zu machen.
Remark!
Hinweis! The follow-up inspections of the adsorption dryer`s
Die Wiederholungsprüfung der Druckluftbehälter compressed-air tanks are subject to national law
des Adsorptionstrockners unterliegen dem natio- and must be carried out in accordance with the
nalstaatlichen Recht und müssen nach den im Ein- regulations applicable in the country in which the
satzland geltenden Regeln durchgeführt werden. dryre is used

11.4 Austausch von Trockenmittel 11.4 Replacement of desiccant

Unter den Betriebsbedingungen für die der Adsorptionstrockner For the rated working conditions of the desiccant dryer, the
ausgelegt ist, hat das Trockenmittel eine Lebensdauer von min- desiccant material has a minimum life time of 5 years, before his
destens 5 Jahren, bevor seine Aufnahmefähigkeit erschöpft ist. receptivity is exhausted.
Zur Kontrolle befindet sich ein Feuchtigkeitsindikator an der Aus- To control the performance of the desiccant, there is a moisture
trittsleitung des Trockners. indicator attached to the air outlet pipe of the dryer.

• Bevor Sie das Trockenmittel wechseln, entlüften Sie den • Unpressurize and switch off the dryer as described in
Trockner wie im Kapitel 11.3 beschrieben und trennen chapter 11.3.
den Trockner von der Spannungsversorgung.
• Remove carefully the drain plug from the desiccant
• Lösen Sie vorsichtig die Entleerungsstutzen an den bei- towers. Let the residual pressure which may still be
den Adsorptionsmittelbehältern, damit ein eventuell vor- present slowly escape (Attention: Desiccant drains).
handener Restdruck langsam entweichen kann (Achtung:
Adsorptionsmittel tritt aus). • Unscrew the upper plugs.

• Lösen Sie die oberen Füllstutzen. • Empty the towers completely.

• Behälter vollständig entleeren. • Mount and seal the drain plug at the desiccant towers.

• Montieren und Eindichten der Entleerungsstutzen an den • Fill the two towers with original desiccant. That ensure
Adsorptionsmittelbehältern. that the dryer will continue to produce compressed-air in
a satisfied quality.
• Füllen Sie die beiden Behälter komplett mit Original-Adsorp-
tionsmittel. Damit ist sichergestellt, daß der Adsorptions- • Mount and seal the plugs at the desiccant towers.
trockner weiterhin Druckluft in zufriedenstellender Quali-
tät liefert. • After replacing the desiccant carry out the complete
commis-sioning procedure as described in chapter 8.
• Montieren und Eindichten der Füllstutzen an den
Adsorptionsmittelbehältern. Remark!
• Nach dem Adsorptionsmittelwechsel ist eine erste Inbe- Keep the containers with the new desiccant closed unitl they are
triebnahme, wie im Kapitel 8. beschrieben durchzufüh- used, to prevent the adsorption of moisture from the ambient air.
ren. If the desiccant has nevertheless become wet, the moisture can
be discharged by heating the adsorption agent for 4 hours at a
Hinweis! temperature of + 200°C.

Halten Sie die Behälter mit dem neuen Adsorptionsmittel bis zum
Gebrauch verschlossen, um die Aufnahme von Feuchtigkeit aus
der Umgebungsluft zu vermeiden.
Ist das Adsorptionsmittel trotzdem feucht geworden, kann die
Feuchtigkeit ausgetrieben werden, indem man das Adsorptions-
mittel für die Dauer von 4 Stunden bei einer Temperatur von 200°C
erhitzt.

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 11. Wartung und Instandhaltung 11. Servicing and maintenance

Hinweis! Remark!
Die in Klammern näher bezeichneten Bauteile (z.B. The components specified in parentheses (e.g.
B006) beziehen sich auf das R&I-Schema. B006) refer to the R&I-schematic diagram.

Warnung! Attention!
Der Adsorptionstrockner steht unter erhöhtem The desiccant dryer contains under high pressure.
Druck. Depressurize the dryer before servicing or
Vor Service- oder Reparaturarbeiten ist das Gerät repairing.
drucklos zu machen.
Remark!
Hinweis! The follow-up inspections of the adsorption dryer`s
Die Wiederholungsprüfung der Druckluftbehälter compressed-air tanks are subject to national law
des Adsorptionstrockners unterliegen dem natio- and must be carried out in accordance with the
nalstaatlichen Recht und müssen nach den im Ein- regulations applicable in the country in which the
satzland geltenden Regeln durchgeführt werden. dryer is used

11.5 Wartungspakete 11.5 Maintenance packages

Für eine optimale Wartung wurden spezielle For ideal maintenance effect a special
Wartungspakete entwickelt, die alle notwendigen maintenance package is developed. All necessary
Wartungsteile enthalten parts are included.

Wartungspaket A Maintenance package A

für 6000 Schraubenkompressoren-Betriebsstunden, max. 1 Jahr for 6000 screw compressor-operating hours, max. 1 year

DC 12E: Mat.-Nr.: 9.5417.1 DC 12E: Mat.-No.: 9.5417.1

DC 18E: Mat.-Nr.: 9.5418.1 DC 18E: Mat.-No: 9.5418.1
DC 27E: Mat.-Nr.: 9.5419.1 DC 27E: Mat.-No.: 9.5419.1
DC 33E: Mat.-Nr.: 9.5420.1 DC 33E: Mat.-No.: 9.5420.1
DC 50E: Mat.-Nr.: 9.5421.1 DC 50E: Mat.-No.: 9.5421.1
DC 75E: Mat.-Nr.: 9.5422.1 DC 75E: Mat.-No.: 9.5422.1
DC 108E: Mat.-Nr.: 9.5423.1 DC 108E: Mat.-No.: 9.5423.1
DC 133E: Mat.-Nr.: 9.5424.1 DC 133E: Mat.-No.: 9.5424.1

bestehend aus: Filterelementen, Schalldämpfer, Service unit ECO- includes: filter cartridges, muffler, service unit ECO-DRAIN,
DRAIN, Feuchteindikator, Batterien moisture indicator, batteries

Wartungspaket B Maintenance package B

für 5-jährigen Betrieb for 5 year operation

DC 12E: Mat.-Nr.: 9.5417.00010 DC 12E: Mat.-No.: 9.5417.00010

DC 18E: Mat.-Nr.: 9.5418.00010 DC 18E: Mat.-No.: 9.5418.00010
DC 27E: Mat.-Nr.: 9.5419.00010 DC 27E: Mat.-No.: 9.5419.00010
DC 33E: Mat.-Nr.: 9.5420.00010 DC 33E: Mat.-No.: 9.5420.00010
DC 50E: Mat.-Nr.: 9.5421.00010 DC 50E: Mat.-No.: 9.5421.00010
DC 75E: Mat.-Nr.: 9.5422.00010 DC 75E: Mat.-No.: 9.5422.00010
DC 108E: Mat.-Nr.: 9.5423.00010 DC 108E: Mat.-No.: 9.5423.00010
DC 133E: Mat.-Nr.: 9.5424.00010 DC 133E: Mat.-No.: 9.5424.00010

bestehend aus: Filterelementen, Schalldämpfer, ECO-DRAIN, includes: filter cartridges, muffler, ECO-DRAIN, moisture indicator,
Feuchteindikator, Druckschalter, Dichtsätze, Ventile, Steuerventile, pressure switch, sealing sets for valves, control valves, batteries,
Batterien, Adsorptionsmittel desiccant

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 12. Technische Daten 12. Technical data
Angaben nach DIN ISO 7183 Option A Specification according to DIN ISO 7183 Option A

Hinweis! Remark!
Bei Veränderungen eines Wertes (*) auf aktuelle Should any data change which is marked with a * all
Betriebsbedingungen ergeben sich Veränderungen other data in that section may also change.
bei allen mit * gekennzeichneten Werten.

Typ / Type DC 12E DC 18E DC 27E DC 33E DC 50E DC 75E DC 108E DC 133E

1. Umgebungstemperatus / Ambient temperature

Min. Umgebungstemperatur
°C +2
Min. ambient temperature

Max. Umgebungstemperatur
°C + 45
Max. ambient temperature

2. Druckluft-System / Compressed air system

Min. Eintrittstemperatur
+2
Min. Inlet temperature

* Eintrittstemperatur
°C + 35
* Inlet temperature

Max. Eintrittstemperatur
+ 50
Max. Inlet temperature

* Austrittstemperatur
°C + 35
* Oulet temperature

* Volumenstrom
(bezogen auf +20°C Druckluftansaug- m3/h
70 110 160 200 300 450 650 800
temperatur und 1 bar absolut)
* Air flow
1,2 1,8 2,7 3,3 5 7,5 10,8 13,3
(relating to +20°C compressed air m3/min
inductiontemperature and 1 bar absolute)

* Drucktaupunkt bei Betriebsüberdruck

°C - 40
* Pressure dewpoint at working pressure

* Betriebsüberdruck
bar 7
* Working pressure

Max. Betriebsüberdruck
bar 16
Max. working presssure

Min. Betriebsüberdruck
bar 5
Min. working presssure

* Differenzdruck Eintritt / Austritt

bar < 0,2
* Differential pressure inlet / outlet

Druckluftanschluß
R 1/2 R 3/4 R1 R1 1/2 R2
Compressed air connection

3. Einstellwerte / Ratings
Druckschalter Behälter Druck min. 0,91 EIN/ON
bar
Pressure switch tower pressure min. 0,7 AUS/OFF

4. Adsorptionsmittel / Desiccant
Adsorptionsmittel Aktivier tes Aluminiumoxid Al2O3
Desiccant Activated aluminia Al2O3

Behälterinhalt
l 24 35 59 93 93 133 160 205
Volume vessel

Füllgewicht je Druckbehälter
kg 18 26 44 70 70 100 120 154
Charge per tower

5. Kondensat / Condensate
Kondensatableitungsanschluß R 1/4 innen
Condensate separator connection R 1/4 female

Der Adsorptionstrockner ist für die angegebenen The desiccant compressed air dryer has been rated
Bedingungen eingestellt. Bei hiervon abweichen- for the conditions mentioned. If you have conditions
den Bedingungen nehmen Sie bitte Rücksprache other than these, please contact the manufacturer
mit dem Hersteller. for advice.

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 12. Technische Daten 12. Technical data
Angaben nach DIN ISO 7183 Option A Specification according to DIN ISO 7183 Option A

Hinweis! Remark!
Bei Veränderungen eines Wertes (*) auf aktuelle Should any data change which is marked with a * all
Betriebsbedingungen ergeben sich Veränderungen other data in that section may also change.
bei allen mit * gekennzeichneten Werten.

Typ / Type DC 12E DC 18E DC 27E DC 33E DC 50E DC 75E DC 108E DC 133E

6. Elektrotechnik / Electrical data

Netzspannung
V 230V + 10%/1/N/PE
Voltage

Frequenz
Hz 50 / 60
Frequency

Nennleistung
kW 0,05
Nominal power

Max. Nennstrom
A 0,2
Max. nominal current

Max. Vorsicherung
A 6
Max. pre-protection

Max. Anschlußquerschnitt
mm2 1,5
Max. connection cross-section

Schutzart
IP 54
Kind of protection

Max. Schalldruckpegel
dB (A) < 88 < 91 < 94 < 109
Max. Noise level chart

7. Maße, Gewicht / Measurements, weights

Höhe / Breite Tiefe
mm 2000/800/800 2000/1200/800
Height / Width / Depth

Gewicht
kg 202 247 297 354 354 504 594 659
Weight

Der Adsorptionstrockner ist für die angegebenen The desiccant compressed air dryer has been
Bedingungen eingestellt. Bei hiervon abweichen- rated for the conditions mentioned. If you have
den Bedingungen nehmen Sie bitte Rücksprache conditions other than these, please contact the
mit dem Hersteller. manufacturer for advice.

Die Druckluftbehälter sind ausgelegt für eine Druck- The compressed-air tanks are suitable for a dynamic
wechselbeanspruchung von 1.000.000 Lastwechsel load of 0,2 - 15 bar at 1.000.000 load changes
(gemäß AD2000-S2, Anhang 4) von 0,2 auf 15 bar (according to AD2000-S2, annex 4).

Hinweis! Remark!
Die Wiederholungsprüfung der Druckluftbehälter The follow-up inspections of the adsorption dryer`s
des Adsorptionstrockners unterliegen dem natio- compressed-air tanks are subject to national law
nalstaatlichen Recht und müssen nach den im Ein- and must be carried out in accordance with the
satzland geltenden Regeln durchgeführt werden. regulations applicable in the country in which the
dryer is used

Hinweis!
Zum Anschluß externer Störmeldesysteme ist das Remark!
Gerät mit einem potentialfreien Kontakt „Sammel- For the connection of external trouble indication
störmeldung“ ausgerüstet. Den Anschluß entneh- systems the dryer is equipped with a potential free
men Sie bitte dem Schaltplan (siehe Kapitel 14). contact „common alarm“. For connections please
see the wiring diagram (chapter 14).

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 Betriebsüberdruck
Working pressure

Eintrittstem peratur
Inlet tem perature
5bar 6bar 7bar 8bar 9bar 10bar 11bar 12bar 13bar 14bar 15bar 16bar
35°C 0,75 0,88 1,00 1,06 1,12 1,17 1,22 1,27 1,32 1,37 1,41 1,46
36°C 0,74 0,87 0,99 1,05 1,11 1,16 1,21 1,26 1,31 1,36 1,40 1,44
37°C 0,74 0,87 0,99 1,05 1,11 1,16 1,21 1,26 1,31 1,36 1,40 1,44
38°C 0,74 0,86 0,98 1,04 1,10 1,15 1,20 1,25 1,30 1,34 1,39 1,43
39°C 0,74 0,86 0,98 1,04 1,10 1,15 1,20 1,25 1,30 1,34 1,39 1,43
40°C 0,74 0,86 0,98 1,04 1,10 1,15 1,20 1,25 1,30 1,34 1,39 1,43
11. Technische Daten

41°C 0,73 0,85 0,97 1,03 1,08 1,14 1,19 1,24 1,28 1,33 1,37 1,41
42°C 0,72 0,84 0,96 1,02 1,07 1,13 1,18 1,22 1,27 1,31 1,36 1,40
43°C 0,71 0,83 0,95 1,01 1,06 1,11 1,16 1,21 1,26 1,30 1,34 1,38
0,71 0,82 0,94 1,00 1,05 1,10 1,15 1,20 1,24 1,29 1,33 1,37
Korrekturfaktoren DC(E) Nennvolumenstrom

44°C

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45°C 0,71 0,82 0,94 1,00 1,05 1,10 1,15 1,20 1,24 1,29 1,33 1,37
46°C 0,70 0,81 0,93 0,99 1,04 1,09 1,14 1,19 1,23 1,27 1,32 1,36
47°C 0,69 0,81 0,92 0,98 1,03 1,08 1,13 1,17 1,22 1,26 1,30 1,34
48°C 0,68 0,80 0,91 0,97 1,02 1,07 1,11 1,16 1,20 1,25 1,29 1,33
49°C 0,68 0,79 0,90 0,95 1,01 1,06 1,10 1,15 1,19 1,23 1,27 1,31
50°C 0,68 0,79 0,90 0,95 1,01 1,06 1,10 1,15 1,19 1,23 1,27 1,31

A3237

D-Name
erstellt
07.03.07 SK

Name
gepr.
07.03.07 KC

Name
11. Technical data

A2826

ersetzt f. ersetzt d.
Correction factors DC(E) for nominal air flow
 Betriebsdruck m it den entsprech end en Lastw echseln für die Adsorptionsm ittelbehälter D C 12 (E ) bis DC 133 (E ) ( Serie II )
W orking press ure w ith the correspondin g lo ad changes for the desiccant tow ers DC12 (E) - DC133 ( E) (S eries II)

15,0 bar
(d elta p 14 ,8 )

14,0 bar
(d elta p 13 ,8 )

13,0 bar
(d elta p 12 ,8 )

12,0 bar
(d elta p 11 ,8 )
12. Technische Daten

11,0 bar
(d elta p 10 ,8 )

- 55 von 67 -
10,0 ba r
(delta p 9,8)

9 ,0 bar
(delta p 8,8)
Dauerfestigkeit na ch S 2 An han g 4 ( N D = 5xE10)
Fatigue lim it according to S 2 annex 4 (ND = 5xE10)
8 ,0 bar

W orking pressure
B etriebsüberdruck
(delta p 7,8)

A3237

D-Name
7 ,0 bar

erstellt
(delta p 6,8)

07.03.07 SK

Name
1000000
2500000
5000000

1 250000
1500 000
20 00000
35000 00
47500 00

gepr.
M ax. zulässiger Lastw echsel / M ax. Load changes

07.03.07 KC

Name
W ird das delta p geringer, erhöht sich entsprechend die Lastspielzahl
12. Technical data

If the delta p becom es sm aller, the load cycle increases appropriate

A2826

ersetzt f. ersetzt d.
13. R&I-Schema 13. P&I-Diagram

A 2348
R&I-Schema / P&I-Diagramm
28.07.2003

DC-12E - DC-133E
Houf
JRo

A3237 07.03.07 SK 07.03.07 KC A2826

- 56 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

 Position Ersatzteil Verschleiß- Benennung Artikel Nr. / Part No.
R&I-Schema Spare teil Description
Position Part Wear-out
P&I-Diagram Part
DC 12E DC 18E DC 27E DC 33E DC 50E DC 75E DC 108E DC 133E

B 006 Adsor ptionsmittelbehälter

B 007 Desiccant vessel

B 006 Adsor ptionsmittel Teil aus War tungspaket B /

B 007 * Desiccant Par t of maintenace package B

Vorfilter
F 001 * FE-18E FE-28E FE-48E FE-71E FE-107E FE-138E
Pre-filter

Filterelement Teil aus War tungspaket A+B /

F 001 * Filter car tridge Par t of maintenace package A+B

Nachfilter
F 012 * FD-18E FD-28E FD-48E FD-71E FD-107E FD-138E
After-filter

Filterelement Teil aus War tungspaket A+B /

F 012 * Filter car tridge Par t of maintenace package A+B

F 004, F 005, Strömungsver teiler

*
F 008, F 009 Strainer

F 016 Schalldämpfer Teil aus War tungspaket A+B /

F 017 * Muffler Par t of maintenace package A+B

Feuchteindikator Teil aus War tungspaket A+B /

MI 021 * Moisture indicator Par t of maintenace package A+B
(Verschleißteile für 1-jährigen Betrieb)

Druckminderer - Steuerluft
PC 036 * 9.3049.06020
Pressure-reducing valve - control air
13. R&I-Schema Stückliste

Filterelement Druckminderer Teil aus War tungspaket B /

PC 036 * Car tridge - pressure-reducing valve Par t of maintenace package B

PDI 001 Filter monitor

* 9.3069.0
PDI 012 Filter monitor

- 57 von 67 -
PDI 018 Manometer - Behälter
* 9.3049.06040
PDI 019 Pressure gauge - vessel

Manometer - Regeneration, hinten

PI 020 * 9.3049.06060
Pressure gauge - purge, behind

Manometer - Regeneration
PI 035 * 9.3049.06050
Pressure gauge - purge

PS 028 Druckschalter Teil aus War tungspaket B /

PS 029 * Pressure switch Par t of maintenace package B

TE 024; TE 025; Temperaturfühler

* 9.3049.01010
TE 026; TE 027 Ther mistor

A3237
Kugelhahn

D-Name
V 001 * 8.0251.0
Ball valve

V 002 Schrägsitzventil NO - Eintritt

* 9.3049.00280 9.3049.00290 9.3049.00300 9.3049.00310
V 003 Inclined-seat valve NO - inlet

erstellt
Wechselventil
V 013 * 9.3049.06070 9.3049.06080 9.3049.06090 9.3049.06100
Shuttle valve

07.03.07 SK
V 014 Schrägsitzventil NC - Regeneration

Name
* 9.3049.00320 9.3049.00330 9.3049.00340 9.3049.00350
V 015 Inclined-seat valve NC - purge

V 022; V 023 3/2-Wege Magnetventil

gepr.
V 030; V 031 * 3/2-way solenoid valve

Regenerationsmengeneinstellventil
V 034 * 9.3049.06120 9.3049.06130 9.3049.06140
Adjustable purge rate valve

07.03.07 KC

Name
V 053 Schnellentlüftungsventil
* - 9.3049.08560
V 054 quick air vent valve
(Wear out parts for one year operation)

Kondensatableiter Teil aus War tungspaket A+B /

X 001 *

A2826
Condensate discharger Par t of maintenace package A+B
13. P&I-Diagram Part-List

R-Blende 1
9.3049.06280 9.3049.06270 9.3049.06260 9.3049.00520 9.3049.06250 9.3049.06240 9.3049.06230 9.3049.06220
R-Orifice 1
X 012
X 013 *
R-Blende 2
9.3049.06210 9.3049.06200 9.3049.06190 9.3049.00530 9.3049.06180 9.3049.06170 9.3049.06160 9.3049.06150
R-Orifice 2

ersetzt f. ersetzt d.
14. Schaltplan 14. Wiring Diagram

A3237 07.03.07 SK 07.03.07 KC A2826

- 58 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

 Position Position Ersatzteil Benennung Artikel Nr. / Part No.
E-Schaltplan R&I-Schema Spare Description
Position Position Part
W- Diagram P&I-Diagram
DC 12E DC 18E DC 27E DC 33E DC 50E DC 75E DC 108E DC 133E

Adsorbersteuerung
- A 30 * 9.3049.05560
Control unit

Kondensatableiter siehe Stückliste R&I

- A 31 X 001
Condensate discharger see part list P&I

Kondensatableiter (Option) siehe Stückliste R&I

- A 34
Condensate discharger (Option) see part list P&I
14. E-Plan Stückliste

Temperaturfühler siehe Stückliste R&I

- B 33 TE 024
Thermistor see part list P&I

Temperaturfühler siehe Stückliste R&I

- B 34 TE 025
Thermistor see part list P&I

- 59 von 67 -
Temperaturfühler siehe Stückliste R&I
- B 35 TE 026
Thermistor see part list P&I

Temperaturfühler siehe Stückliste R&I

- B 36 TE 027
Thermistor see part list P&I

Druckschalter siehe Stückliste R&I

- S 36 PS 029
Pressure switch see part list P&I

A3237

D-Name
Druckschalter siehe Stückliste R&I
- S 37 PS 028

erstellt
Pressure switch see part list P&I

07.03.07 SK
Magnetventil - Eintritt siehe Stückliste R&I

Name
- Y 31 V 030
Solenoid valve - inlet see part list P&I

gepr.
Magnetventil - Regeneration siehe Stückliste R&I
- Y 32 V 022
Solenoid valve - purge see part list P&I

07.03.07 KC

Name
Magnetventil - Eintritt siehe Stückliste R&I
- Y 33 V 031
Solenoid valve - inlet see part list P&I

A2826
14. Wiring-Diagram Part-List

Magnetventil - Regeneration siehe Stückliste R&I

- Y 34 V 023
Solenoid valve - purge see part list P&I

ersetzt f. ersetzt d.
15. Maßzeichnung 15. Dimensional drawing

A 2321
25.07.2003
Houf

DC - 12E
JRo

A3237 07.03.07 SK 07.03.07 KC A2826

- 60 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

15. Maßzeichnung 15. Dimensional drawing

A 2323
25.07.2003
Houf

DC - 18E
JRo

A3237 07.03.07 SK 07.03.07 KC A2826

- 61 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

15. Maßzeichnung 15. Dimensional drawing

A 2325
25.07.2003
Houf

DC - 27E
JRo

A3237 07.03.07 SK 07.03.07 KC A2826

- 62 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

15. Maßzeichnung 15. Dimensional drawing

A 2327
28.07.2003
Houf

DC - 33E
JRo

KAESER Kompressoren

A3237 07.03.07 SK 07.03.07 KC A2826

- 63 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

15. Maßzeichnung 15. Dimensional drawing

A 2329
28.07.2003
Houf

DC - 50E
JRo

A3237 07.03.07 SK 07.03.07 KC A2826

- 64 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

15. Maßzeichnung 15. Dimensional drawing

A 2331
28.07.2003
Houf

DC - 75E
JRo

A3237 07.03.07 SK 07.03.07 KC A2826

- 65 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

15. Maßzeichnung 15. Dimensional drawing

A 2333
28.07.2003

DC - 108E
Houf
JRo

A3237 07.03.07 SK 07.03.07 KC A2826

- 66 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

15. Maßzeichnung 15. Dimensional drawing

A 2335
28.07.2003

DC - 133E
Houf
JRo

A3237 07.03.07 SK 07.03.07 KC A2826

- 67 von 67 - D-Name erstellt Name gepr. Name ersetzt f. ersetzt d.

 www.kaeser.com www.kaeser.com

Explanation:
Choose the required grade of treatment according to your field of application:
THNF = Bag filter
Air treatment using a refrigeration dryer (+3°C pressure dew point) Cleans dusty and contaminated intake air
Examples: Selection of treatment classes to ISO 8573-1 1) CS = Cyclonic separator
Installation for heavily
Solids Water Oil Bacteria Upon fluctuating air demand Separates accumulating condensate

KAESER
< request

KAESER
Pure air and cleanroom Upon ED = Eco-drain
technology request 0 4 1 Electronic level-controlled condensate drain

KAESER

KAESER
KAESER
FST FB = Pre-filter 3 μm

KAESER
< <
Dairies, Breweries A 1 4 1 Filter FC = Pre-filter 1 μm
Air receiver RD CS

KAESER
* FD = Particulate filter 1 μm (attrition)
Food and semi-luxury food < <
B FE = Micro-filter 0.01 ppm

KAESER
production 1 4 1

KAESER
KAESER
AMCS FD ACT FF Separates aerosol oil and solid particles
Very clean conveying air, < FE FF = Micro-filter 0.001 ppm
chemical plants C 2 4 1 Separates aerosol oil and solid particles
AMCS
Upon
KAESER
request FG = Activated carbon filter
Pure air and cleanroom Upon < For adsorption of oil vapours
technology request 0 4 1

KAESER
FFG = Activated carbon and micro-filter
*
KAESER

< < FST combination

KAESER
Pharmaceutical industry A 1 4 1

KAESER
FFG RD = Refrigeration dryer

KAESER
For drying compressed air, pressure dew point
< < to +3 °C
Weaving machines, photo labs B 1 4 1 RD ED Compressor THNF
AMCS * DD = Desiccant dryer
For drying compressed air, pressure dew point
<

KAESER
<
Paint spraying, powder coating D 1 4 1
to -70 °C
AMCS FF
* ACT = Activated carbon adsorber
Packaging, control and < < For adsorption of oil vapours
KAESER

instrument air E 1 4 2 FST = Sterile filter

AMCS FE
For sterile compressed air
General works air, Aquamat = Condensate treatment system
high-grade sand blasting G 2 4 3
AMCS AMCS = Air-main charging system
FC

Filters & Centrifugal Separators

KAESER

Shot blasting G 2 7 3 Aquamat

Low-grade shot blasting FB

KAESER

H 3 7 4 Air flow rate 0.58 to 248 m3/min

Contaminants:
KAESER rotary screw compressors *FE micro-filters + Solids –
Conveying air for waste water I 3 9 4 can be optionally
installed in TG to TI + Water/ Condensate –
Other machines series refrigeration + Oil –
No quality requirements J dryers.
8 9 5 + Bacteria –
For air mains subject to sub-zero temperatures: Compressed air treatment with a desiccant dryer (pressure dew point to -70 °C)
Degree of filtration:
Solids Water Oil Bacteria Upon
KAESER

Pure air and cleanroom < request Solid particles1) Humidity Total oil
Upon content
technology request 0 1-3 1
Class ISO 8573-1

Installation for heavily

Max.particle Max.particle Pressure dew
KAESER

Pharmaceutical industry, < < FST fluctuating air demand

dairies, breweries A 1 1-3 1 size concentration point point
KAESER

(x = liquid water
KAESER
KAESER

μm mg/m3 in g/m3) mg/m3

Microchip production, optics, food < <
KAESER

B
KAESER

and semi-luxury food production 1 1-3 1 FE FD ACT

KAESER

AMCS 0 e.g. Consult Kaeser regarding pure air and cleanroom

KAESER

KAESER

Filter technology
<
Paint spraying C 2 1-3 1 AMCS
Air receiver DD FE CS 1 0.1 0.1
Upon 2 1 1
KAESER

Pure air and cleanroom Upon < request

request 0 3 5 5
technology 1-3 1
KAESER

4 15 8
KAESER
KAESER

< < FST 5 40 10

KAESER

Process air, pharmaceutical A 1 1-3 1 6 – –

industry
7 – –
KAESER

< <
Photo labs B 1 1-3 1 Compressor THNF 8 – –
KAESER

KAESER

AMCS FG FD DD FE ED
9 – –
Especially dry conveying air, paint
spraying, fine pressure controllers F 2 1-3 1 Aquamat
1
) Particle load as per ISO 8573-1:1991
AMCS
A D H
E I
P-725ED.15/07 Specifications are subject to change without notice

B F J Untreated
C G

KAESER KOMPRESSOREN GmbH

P. O. Box 2143 – 96410 Coburg – GERMANY – Tel: +49 9561 640-0 – Fax: +49 9561 640130
www.kaeser.com – e-mail: productinfo@kaeser.com
 KAESER Compressed air filters Air filters
Kaeser's extensive range of
Dependable and efficient filters ensures that there's a
model available to suit every
Why use compressed compressed air need.
air filters? Water, oil and dust are
removed efficiently and with
Tailored compressed
minimal differential pressure.
On average, a compressor sucks in up to 190 air treatment
million particles of dirt, hydrocarbons, viruses and All Kaeser filters and compressed air
treatment components are specifically
bacteria with every cubic meter of atmospheric air. designed for use in combination with Sterile filter
The compressor itself can only remove the larger one another.
Centrifugal separator
dirt particles and the majority of the contaminants Compressed air of every quality
class is available ranging from For removal of liquid conden-
remain in the compressed air. This means that for general works air right up to sate. Typically used downstream
most applications careful treatment of the air is foodstuff and pharmaceutical from the compressor. Results
grade air. KAESER compressed in near 100 % relative humidity,
necessary: Clean, quality compressed air maxim- air filters are also available for which is ideal for further drying
ises air-tool service life, ensures that pneumatic high-pressure applications up systems.
to 62 bar(g).
machinery and control systems operate at the peak
of their performance and keeps pipes & valves free
from contaminants. It therefore not only reduces
service, maintenance and repair costs, but can also
Filters up to 48
reduce initial investment costs. or 62 bar
We also have an extensive

KAESER filters ensure range of filters available for

high-pressure applications,
a dependable and Centrifugal separator
such as PET container

cost-effective source of production. Suited for use

with pressures of up to 48
quality compressed air 1
2
High-pressure filter
or 62 bar, these high-quality
filters remove oil, water and
Compressed air filters from KAESER KOMPRES- dust.

SOREN are ideally suited for use with our com- 3

pressors and compressed air drying systems. This 4 Sterile filter

Air filters
ensures dependable compressed air treatment and These exceptionally reliable
sterile filters are perfect for
exceptional efficiency. 1 Compressed air inlet applications that require ster-
2 Compressed air outlet ile, bacteria-free compressed
air, such as the food and
3 Filter housing
pharmaceuticals industries.
4 Filter element
5 Electronically controlled ECO
DRAIN condensate drain

Certified: Clean compressed air

Kaeser compressed air systems provide the required grade of compressed air
5 quality to suit every compressed air application. This includes technically oil-
free compressed air, which is many times cleaner than normal ambient air.
All systems and equipment are tested and certified by the German Technical
Inspection Institute (TÜV).
 The right degree of filtration for every

Compressed air filters compressed air need

Use: For removal of solid particles and larger volumes of
condensate.
To be used as a pre-filter for solid particles and for removal of
Perfectly matched to compressor and compressed air treatment equipment, larger volumes of condensate.
Kaeser’s extensive range of filters ensures that all relevant compressed air quality Size of particles removed: > 3 μm
classes are maintained reliably and efficiently over the long-term. Max. fluid load at inlet: 25 g/m³

FB pre-filter 3 μm

Use: For removal of solid particles and small volumes of condensate.

To be used as a pre-filter for solid particles and for removal of
small volumes of condensate.
Filter change maintenance indicator A centrifugal separator or an air receiver should be installed upstream
to provide initial removal of condensate.
The filter monitor ... (optional) Size of particles removed: > 1 μm
Max. fluid load at inlet: 2 g/m³
... indicates when filter change is required.
• Microprocessor-controlled LCD display
• Comprehensive filter monitoring based on: FC pre-filter 1 μm
- operating time
- differential pressure Use: For removal of solid particles
- operation efficiency: comparison of increasing energy requirement caused by filter clogging
To be used only as a dust filter for solid particles, often used
to a maximum value that is dependent on the operating conditions and downstream from desiccant dryers and activated carbon adsorbers.
which is calculated by the monitor Through-flow from outside to inside – ensures exceptionally high dust
• Significant energy savings load capacity and maximum reliability.
• ‘Filter change’ warning with red LED and alarm contact Size of particles removed: > 1 μm
• Continuous measurement of pressure differential to an accuracy of 0.025 bar via precision Max. fluid load at inlet: Compressed air must be dry
pressure transducer
• Direct data input, no separate programming device required
FD dust filter

The high performance filter element ...

Use: For removal of fine solid particles, condensate droplets and
... ensures reliable filtration with minimal pressure losses: oil aerosols.
• Coalescence filter with new, matrix filter-fibre structure For use as a fine filter for enhanced compressed air quality.
• High efficiency even at low air volumes of only The filter removes solid particles, condensate droplets and oil
five percent of nominal flow aerosols.
• Reliable element-to-housing seal Size of particles removed: > 0.1 μm
• Stainless steel orifice tubes, oil & acid resistant coated sleeves and end caps Max. fluid load at inlet: 1 g/m³

The filter housing ... FE fine micro-filter

... that lasts:
• Long service life thanks to the epoxy resin coating inside and out Use: For removal of solid particles, the smallest of condensate
(proven in over 1000 hours of salt contamination tests) droplets and oil aerosols.
• Easy filter element removal with Kaeser's O-ring seal system The high capacity filter ensures exceptional compressed air quality
• Minimal pressure drop due to optimised air flow in accordance with the most stringent requirements, e.g. for the
pharmaceutical, electronics and foodstuff industries. Preferably use
• The conical bowl and turbulence-free lower filter zone prevent condensate only with condensate-free compressed air. Ensure that an FE filter or a
from being carried along with the air flow refrigeration dryer is installed upstream from this filter.
• Audible warning should leakages occur Size of particles removed: > 0.1 μm
FFG micro-filter Max. fluid load at inlet: 0.1 g/m³
combination comprises: FF finest micro-filter
The shut-off valve ... FF micro-filter and FG
activated carbon filter Use: For removal of oil and adsorbable hydrocarbons, particularly
... allows maintenance of the condensate drain without interrupting air supply
suited to odour elimination.
Available without
The activated carbon filter ensures exceptional compressed air quality
Condensate drainage with the ECO Drain (optional) ... electronic condensate in accordance with the most stringent requirements, e.g. for the
drain pharmaceutical, electronics and food / beverage industries.
... is electronically level-controlled and fully automatic, which means: Compressed air must be dried and filtered beforehand. Ensure that a
FE/FF filter and a dryer are installed upstream from this filter.
• No air losses
• Exceptional reliability Designed for approx. 1000 operating hours under reference conditions.
Use an activated carbon adsorber if significantly longer service life is
required.
FG activated carbon filter
Size of particles removed: > 0.1 μm
Max. fluid load at inlet: Compressed air must be dry
Max. working pressure 16 bar
Max. working temperature +66 °C
 Centrifugal Sterile
separator filter
Function: For sterile air:
The centrifugal separator removes large volumes The FST sterile filter is made of high quality 1.4301
of condensate from the compressed air. Optimised (304) stainless steel that prevents bacterial growth and
design enhances the centrifuge effect and ensures a corrosion. The upper and lower housings are fitted with
near constant degree of condensate separation over a BSP screw connections and plugs. All filter elements
wide flow volume range. Furthermore, particles up to are subjected to multiple testing in the factory to ensure
5 μm are also "washed out". unrivalled reliability.
All components comply with FDA regulations concern-
ing contact with foodstuffs as per CFR (Code of Federal
Application:
Regulations) Title 21.
A cyclonic separator is recommended for systems
The pre-filter and micro-fibre web are made from of
where the refrigeration dryer is installed “directly”
borosilicate. Retention of bacteria and particles occurs
downstream from the rotary screw compressor.
throughout the whole filter volume. On average, over 100
sterilisation cycles are possible with saturated steam at
The centrifugal separator is installed between the 141 °C.
compressor and the refrigeration dryer and removes Max. operating temperature -20 to +200 °C.
the ‘liquid condensate’ from the compressed air. This
provides the refrigeration dryer with additional reserve
drying capacity. This is particularly important at high Typical uses for FST sterile filters:
ambient temperatures in order to ensure that the
required dew point is consistently maintained. • Food and chemical industries

• Packaging applications

KAESER centrifugal separators are maintenance-free. • Pharmaceuticals, medical technology, hospitals

Tip: Tip:
Each centrifugal separator should be fitted with an The use of a sterile filter requires appropriate sterilisa-
electronic ECO Drain condensate drain (available as tion measures to be taken (e.g. in-line sterilisation or
a complete set with all necessary components). autoclave). These measures should be carried out at
regular intervals.

Centrifugal separator
ZK 061 to ZK 10

Consistent degree of separation FST sterile filter KAESER sterile filters for bacteria-free compressed air
100 100
KAESER centrifugal separator 99
Water separation efficiency in %

99 98
100 % bacteria-free compressed air

Degree of sterilisation in %
97
98 96
95
97 Electronically controlled condensate 94
drain (recommended) 93
96 Complete set with installation components 92
91
95 90
20 40 60 80 100 120 140 160 180 200 220 30 40 50 60 70 80 90 100 110 120
Flow capacity (% of nominal capacity)
Flow capacity (% of nominal capacity)
Filters for 48 or 62 bar
48/62 bar filters for every compressed air need

Use: For removal of solid particles and larger volumes of

condensate.
KAESER high-pressure 48/62 bar filters are available for installation at the booster outlet for special To be used as a pre-filter for solid particles and for removal of
larger volumes of condensate.
high-pressure applications, e.g. PET container production. These also ensure certified compressed air quality.
Size of particles removed: > 3 μm
Max. fluid load at inlet: 25 g/m³

FB filter
Filter housing
Durable, pressure-resistant steel housing
Use: For removal of solid particles and small volumes of
condensate.
Filter elements To be used as a pre-filter for solid particles and for removal of
small volumes of condensate.
Five different filter elements - ranging from pre-filters to activated carbon filters - are avail- A centrifugal separator or an air receiver should be installed upstream
able for pressures up to 62 bar to provide initial removal of condensate.
Size of particles removed: > 1 μm
Special electronic condensate drain (optional) Max. fluid load at inlet: 2 g/m³

KAESER high-pressure filters can also be equipped with an electronically controlled ECO
Drain condensate drain (PN 63). FC filter

Use: For removal of fine solid articles, condensate

droplets and oil aerosols.
For use as a fine filter for enhanced compressed air quality.
For removal of solid particles, condensate droplets and oil
aerosols.
Size of particles removed: > 0.1 μm
Max. fluid load at inlet: 1 g/m³

FE filter

Use: For removal of finest solid articles, the smallest

condensate droplets and oil aerosols.
This high-performance filter ensures exceptional compressed
air quality in accordance with the most stringent requirements,
e.g. for the pharmaceutical, electronics and food / beverage
industries. Preferably use only with condensate-free
compressed air. Ensure that an FE filter or a refrigeration
dryer is installed upstream from this filter.
Size of particles removed: > 0.1 μm
Max. fluid load at inlet: 0.1 g/m³

FF filter

Use: For removal of oil and adsorbable hydrocarbons, particularly

Compressed air systems with boosters suited to odour elimination.
Schematic illustration The activated carbon filter ensures exceptional compressed air
quality in accordance with the most stringent requirements, e.g.
High pressure
micro-filter for the pharmaceutical, electronics and food / beverage industries.
Low pressure network Pre-filter Use only with compressed air that has already been dried and
up to 13 bar filtered. Ensure that a FE/FF filter and a dryer are installed
Com- upstream from this filter.
pressed
air net- Designed for approx. 1000 operating hours under reference
work conditions. Use an activated carbon adsorber (ACT series) if
Air tools at 45 bar significantly longer service life is required.
Size of particles removed: > 0.1 μm
FG filter Max. fluid load at inlet: Compressed air must be dry
Rotary screw Air receiver Booster High pressure High pressure
compressor air receiver refrigeration dryer
Max. working pressure 48 or 62 bar
Technical specifications
Designation:
Filter housing Replacement filter elements
Filter series: FB, FC, FD, FE, FF, FG, FFG – Filter sizes: 6, 10, 18, 28, 48, 71, 107, 138, 177, 221, 185, 283, 354, 526, 708, 885, 1420, 1950, 2480
Filter series Version Series Size
Versions: "Normal" with float-controlled drain – "D" With electronic level-sensing controlled ECO DRAIN condensate drain
Aluminium casing for filter sizes from 6 to 221, Steel casing for filter sizes from 185 to 2480
FE 221 D E-E-221
Compressed air filter for max. 16 bar, max. operating temp. +66C Size Replacement filter elements Replacement filter element
A

Flow rate *) Filter Air Weight kg Dimensions A, B, C in mm Removal height Filter No. Replacement filter elements
m³/min size connection (Standard version) (Standard version) (for maintenance) size
FB – FFG FB – FFG FB – FC FD FE – FF FG FFG FB – FC FD FE – FF FG FFG mm
FB FC FD FE FF FG
0.58 6 R 3/8 3.6 3.5 3.6 3.4 7.1 105, 233, 163 105, 306, 224 105, 306, 224 105, 182, 163 210, 306, 224 76 6 1 E-B-6 E-C-6 E-D-6 E-E-6 E-F-6 E-G-6
1.0 10 R 1/2 3.7 3.6 3.7 3.5 7.3 105, 306, 224 105, 306, 224 105, 306, 224 105, 255, 244 210, 306, 224 76 10 1 E-B-10 E-C-10 E-D-10 E-E-10 E-F-10 E-G-10

B
1.75 18 R 1/2 3.9 3.8 3.9 3.7 7,7 105, 367, 285 105, 367, 285 105, 367, 285 105, 316, 285 210, 367, 285 76 18 1 E-B-18 E-C-18 E-D-18 E-E-18 E-F-18 E-G-18

C
2.83 28 R 3/4 4.4 4.3 4.4 4.2 8.7 133, 389, 298 133, 389, 298 133, 389, 298 133, 338, 298 266, 389, 298 89 28 1 E-B-28 E-C-28 E-D-28 E-E-28 E-F-28 E-G-28
4.83 48 R1 4.8 4.7 4.8 4.6 9.5 133, 497, 406 133, 497, 406 133, 497, 406 133, 446, 406 266, 497, 406 89 48 1 E-B-48 E-C-48 E-D-48 E-E-48 E-F-48 E-G-48
7.1 71 R 1 1/2 4.6 4.5 4.6 4.4 9.1 164, 579, 482 164, 579, 482 164, 579, 482 164, 528, 482 328, 579, 482 102 71 1 E-B-48 E-C-71 E-D-71 E-E-71 E-F-71 E-G-71
10.7 107 R 1 1/2 5.1 5.0 5.1 4.9 10.1 162, 693, 596 164, 693, 596 164, 693, 596 164, 642, 596 328, 693, 596 102 107 1 E-B-107 E-C-107 E-D-107 E-E-107 E-F-107 E-G-107
13.8 138 R2 12.7 12.6 12.7 12.5 25,3 194, 789, 681 194, 789, 681 194, 789, 681 194, 739, 681 388, 789, 681 102 138 1 E-B-138 E-C-138 E-D-138 E-E-138 E-F-138 E-G-138 Removal height

17.7 177 R 2 1/2 15 14.9 15 14.8 29.9 194, 935, 827 194, 935, 827 194, 935, 827 194, 885, 827 388, 935, 827 102 177 1 E-B-177 E-C-177 E-D-177 E-E-177 E-F-177 E-G-177
A
22.1 221 R 2 1/2 17.2 17.1 17.2 17 34.3 194, 1091, 983 194, 1091, 983 194, 1091, 983 194, 1040, 983 388, 1091, 983 102 221 1 E-B-138 E-C-221 E-D-221 E-E-221 E-F-221 E-G-221
18.5 185 DN 80 29.9 28.4 29.3 28.6 58.6 350, 1130, 950 350, 1025, 845 350, 1130, 950 350, 1025, 845 700, 1130, 950 610 185 1 E-B-185 E-C-185 E-D-185 E-E-185 E-F-185 E-G-185
28.3 283 DN 80 41.1 37.0 40.1 37.2 78 400, 1205, 1013 400, 1045, 853 400, 1205, 1013 400, 1045, 853 800, 1205, 1013 610 283 2 E-B-283 E-C-283 E-D-283 E-E-283 E-F-283 E-G-283
35.4 354 DN 100 41.8 37.4 40.5 38.1 79.3 400, 1240, 1013 400, 1045, 853 400, 1205, 1013 400, 1045, 853 800, 1205, 1013 610 354 2 E-B-185 E-C-185 E-D-185 E-E-185 E-F-185 E-G-185
52.6 526 DN 100 53.4 48.4 51.5 49.7 101.9 440, 1240, 1023 440, 1085, 868 440, 1240, 1023 440, 1085, 868 880, 1240, 1023 610 526 3 E-B-185 E-C-185 E-D-185 E-E-185 E-F-185 E-G-185

B
70.8 708 DN 100 70 64.4 66.7 66.2 133.6 535, 1255, 1022 535, 1105, 872 535, 1255, 1022 535, 1105, 872 1070, 1255, 1022 610 708 4 E-B-185 E-C-185 E-D-185 E-E-185 E-F-185 E-G-185

C
88.5 885 DN 100 71.7 65,4 67.7 67.8 136.2 535, 1255, 1022 535, 1105, 872 535, 1255, 1022 535, 1105, 872 1070, 1255, 1022 610 885 5 E-B-185 E-C-185 E-D-185 E-E-185 E-F-185 E-G-185
142 1420 DN 150 126.5 118.4 121.5 122.4 244.6 600, 1355, 1043 600, 1215, 903 600, 1355, 1043 600, 1215, 903 1200, 1355, 1043 610 1420 8 E-B-185 E-C-185 E-D-185 E-E-185 E-F-185 E-G-185
195 1950 DN 150 182.8 171.4 175.9 177.1 353.7 720, 1520, 1183 720, 1245, 908 720, 1520, 1183 720, 1245, 908 1440, 1520, 1183 610 1950 11 E-B-185 E-C-185 E-D-185 E-E-185 E-F-185 E-G-185
Removal height
248 2480 DN 150 237.7 224.4 228.9 231.7 461.3 750, 1540, 1192 750, 1265, 917 750, 1540, 1192 750, 1265, 917 1500, 1540, 1192 610 2480 14 E-B-185 E-C-185 E-D-185 E-E-185 E-F-185 E-G-185
Correction factors
Working pressure bar 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
A
Conversion factor for flow rate 0.38 0.52 0.63 0.75 0.88 1 1.13 1.26 1.38 1.52 1.65 1.76 1.87 2 2.14

Designation:
High-pressure filter Replacement filter elements
Filter series "High Pressure" Filter series "High Pressure"

FB 18 HP 62 E-E-18/28 HP 62
Filters for 48 or 62 bar Filter Size Max. pressure
Replacement filter elements Replacement
Size Max.
filter element pressure

Flow Filter Air Weight Dimensions A, B Removal Max. Filter No. Replacement filter elements

B
rate *) size connec- kg mm height working size for high-pressure filter series
m³/min tion pressure
FB FC FE FF FG FB FC FE FF FG mm bar FB FC FD FE FF
1.75 18 R 1/2 9 371 x 146 300 62 18 1 E-B-18/28 E-B-18/28 E-B-18/28 E-B-18/28 E-B-18/28

2.83 28 R1 9 371 x 117 300 62 28 1 E-B-18/28 E-B-18/28 E-B-18/28 E-B-18/28 E-B-18/28

7.1 71 R1 12 591 x 117 520 48 71 1 E-B-71 E-C-71 E-E-71 E-F-71 E-G-71

14.2 142 DN 65 35 930 x 350 650 48 142 1 E-B-283 E-C-283 E-E-283 E-F-283 E-G-283
Correction factors
Working pressure bar 7 25 40 64 Removal height
Conversion factor for flow rate 1 3 5 8

*) Air flow at 7 bar (g) referred to 1 bar (a) and 20 °C

Technical specifications Designation:
Sterile filter Replacement filter elements
Size "Sterile"

Removal height
F 6 P-ST Replace- 03/10 P-ST
Sterile filter Filter "Sterile"
ment filter Filter
Flow rate *) Filter size Air connection Weight Dimensions A, B, C Removal height Filter No. Replacement filter element
m³/min kg mm (for maintenance) size for sterile filter
(upwards) mm
1 6 R 1/4 1.7 215, 108, 55 90 6 1 03/10 P-ST
1.5 9 R 3/8 1.9 245, 108, 55 120 9 1 04/10 P-ST
2 12 R 1/2 1.9 245, 108, 55 120 12 1 04/20 P-ST
3 18 R 3/4 2 270, 125, 55 150 18 1 05/20 P-ST

A
4.5 27 R1 2.6 300, 125, 75 150 27 1 05/25 P-ST
6 36 R 1 1/4 3 350, 140, 75 200 36 1 07/25 P-ST
8 48 R 1 1/4 4.3 380, 170, 94 200 48 1 07/30 P-ST
12 72 R2 4.8 455, 170, 94 280 72 1 10/30 P-ST
18 108 R2 5.3 580, 170, 94 450 108 1 15/30 P-ST
24 144 R 2 1/2 9 765, 216, 106 580 144 1 20/30 P-ST
32 192 R3 10.8 1015, 216, 106 850 192 1 30/30 P-ST
288 1 30/50 P-ST

C
48 288 R3 16.2 1035, 240, 119 850
Correction factors
Working pressure bar 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B
Conversion factor for flow rate 0.36 0.5 0.6 0.75 0.9 1 1.1 1.2 1.4 1.5 1.6 1.75 1.9 2 2.1 Sterile filter

B
B

Centrifugal separator for max. 16 bar

Flow rate *) Model Air connection Volume Weight Dimensions
m³/min AxBxØ
7 bar 10 bar l kg mm

0.2 2.3 ZK 01 G 3/4 0.8 1.1 292 x 89 x –

4.1 5.0 ZK 02 G1 1.8 2.2 391.5 x 109 x –

A
6 7.3 ZK 03 G 1 1/4 1.8 2.2 391.5 x 109 x –
9.3 11.3 ZK 04 G 1 1/2 1.8 2.2 391.5 x 109 x –
15.2 18.0 ZK 05 G2 5.3 4.3 575 x 150 x –
16.3 19.3 ZK 061 DN 65 11.0 22.0 654 x 370 x 168.3
26.4 31.3 ZK 071 DN 65 17.5 28.0 733 x 400 x 193.7
26.4 31.3 ZK 072 DN 80 18.0 30.0 733 x 400 x 193.7
46.1 55.4 ZK 08 DN 125 35.5 50.0 865 x 450 x 244.5
30.6 36.7 ZK 081 DN 80 34.0 44.0 892 x 460 x 244.5
36.8 43.6 ZK 091 DN 80 47.0 52.0 983 x 550 x 273
47.7 56.9 ZK 09 DN 125 50.0 60.0 983 x 550 x 273 Ø
80 95.8 ZK 10 DN 150 76.0 74.5 1082 x 570 x 324 Centrifugal separator Centrifugal separator
ZK 01 to ZK 05
*) Air flow at 7 bar (g) referred to 1 bar (a) and 20 °C
KAESER filters – Options and accessories
The filter monitor Filter monitor box Wall Bracket Certified Genuine KAESER replacement filter elements
Indicates when filter change is The Filter Monitor Box allows remote Simple installation: Compressed Air Only genuine KAESER replacement filter elements ensure reliable filtration
required. filter monitoring. It evaluates the • Remove differential pressure Quality with minimal pressure losses.
• Indicates filter changes based on signals from a filter monitor, as well as indicator, remove fixing screws
• Coalescence filter with new, matrix
prescribed operational parameters from an ECO Drain condensate drain, • Screw the bracket The oil and filter-fibre structure
and can pass messages to a central to the wall solid particle • High efficiency even at low air volumes of
maintenance control system via two • Screw the filter content is only five percent of nominal flow
alarm contacts. housing to the reliably kept • Reliable element to housing seal
bracket below ISO • Element supported by oil and acid
• Re-install 8573-1 resistant stainless steel orifice tubes and
the differential Class 1 limits. end caps
pressure After passing
indicator through the KAESER replacement filter elements
air treatment are also available for other housings.
• Continuous measurement using systems, the
intelligent electronics Modular design delivered compressed air is des-
• Easy-to-read LCD display, ignated as technically oil-free.
Group alarm The specially designed housing allows
alarm LED The quality of the air produced
(volt-free contact) various filters to be combined together
• Digital display of pressure drop by the KAESER compressed air
in series without the need for additional
• Indication of (time-controlled) system is tested and certified
service interval for filter element
piping. Timely filter changes significantly reduce
by TÜV, the German Technical
Condensate drain change energy costs
Inspection Authority.
ECO DRAIN • Indication of optimum time for filter
Operational parameters: 6000 operating hours/year - 0.06 €/kWh - 1 bar = 8 % more energy
• Non-wearing element change computed via 2500
electronic measurement value processing Note: Please also consider
2000 110 kW
sensor, no • Maximum differential pressure KAESER Air Main Charging Example: With a 75 kW
exceeded (2 minute delay)

Annual energy costs in Euros

moving parts Systems (See brochure P773), 1750 compressed air system, approx.
• Maximum reliability, no sticking • Condensate drain alarm as these also help to ensure 1100 €/year can be saved.

Compressor power
1500
or clogging consistent compressed air 75 kW
Safety alarm
• No compressed air losses quality. 1250
(volt-free contact only active in 1100
• Test button 1000
active safety mode)
• Self-monitoring electronics with
750 45 kW
automatic alarm sequence • Maximum differential pressure
• Volt-free alarm contact exceeded (5 second delay) 500
30 kW
• LEDs for power supply and 22 kW
250
alarm 11 kW
The power supply for the filter monitor
• AC and DC versions (50 / 60 Hz) 0
and ECO-Drain is provided by the Filter 0 0.1 0.2 0.3 0.4 0.5
available
monitor box. Pressure drop in bar
• All controls are water-resistant as
per IP 65

Reduce operating costs

A pressure loss of only approx. 0.35 bar is significantly more expensive
Comprehensive design know-how than the costs required to change the filter element. Timely filter changes
KESS (KAESER’s Energy Saving save considerable operating costs.
Service) provides comprehensive
analysis of your compressed air usage, Pressure Costs Filter
loss elements
enabling KAESER’s experts to plan 0.7 bar = 200 %
and design a system that is specially
0.6 bar = 170 %
tailored to meet all of your compressed

Investment costs
air needs. Typically ensuring a 95-98% 0.5 bar = 145 %
load capacity, KAESER compressed air 0.4 bar = 115 %
systems provide exceptional efficiency Filter element costs 0.35 bar = 100 %
0.3 bar = 85 %
and produce application-specific quality
compressed air at lowest possible cost. 0.2 bar = 60 %
Use this expertise to your advantage and
0.1 bar = 25 %
let KAESER design your compressed air
system.
Operating time
 www.kaeser.com www.kaeser.com

Explanation:
Choose the required grade of treatment according to your field of application:
THNF = Bag filter
Air treatment using a refrigeration dryer (+3°C pressure dew point) Cleans dusty and contaminated intake air
Examples: Selection of treatment classes to ISO 8573-1 1) CS = Cyclonic separator
Installation for heavily
Solids Water Oil Bacteria Upon fluctuating air demand Separates accumulating condensate

KAESER
< request

KAESER
Pure air and cleanroom Upon ED = Eco-drain
technology request 0 4 1 Electronic level-controlled condensate drain

KAESER

KAESER
KAESER
FST FB = Pre-filter 3 μm

KAESER
< <
Dairies, Breweries A 1 4 1 Filter FC = Pre-filter 1 μm
Air receiver RD CS

KAESER
* FD = Particulate filter 1 μm (attrition)
Food and semi-luxury food < <
B FE = Micro-filter 0.01 ppm

KAESER
production 1 4 1

KAESER
KAESER
AMCS FD ACT FF Separates aerosol oil and solid particles
Very clean conveying air, < FE FF = Micro-filter 0.001 ppm
chemical plants C 2 4 1 Separates aerosol oil and solid particles
AMCS
Upon
KAESER
request FG = Activated carbon filter
Pure air and cleanroom Upon < For adsorption of oil vapours
technology request 0 4 1

KAESER
FFG = Activated carbon and micro-filter
*
KAESER

< < FST combination

KAESER
Pharmaceutical industry A 1 4 1

KAESER
FFG RD = Refrigeration dryer

KAESER
For drying compressed air, pressure dew point
< < to +3 °C
Weaving machines, photo labs B 1 4 1 RD ED Compressor THNF
AMCS * DD = Desiccant dryer
For drying compressed air, pressure dew point
<

KAESER
<
Paint spraying, powder coating D 1 4 1
to -70 °C
AMCS FF
* ACT = Activated carbon adsorber
Packaging, control and < < For adsorption of oil vapours
KAESER

instrument air E 1 4 2 FST = Sterile filter

AMCS FE
For sterile compressed air
General works air, Aquamat = Condensate treatment system
high-grade sand blasting G 2 4 3
AMCS AMCS = Air-main charging system
FC

Filters & Centrifugal Separators

KAESER

Shot blasting G 2 7 3 Aquamat

Low-grade shot blasting FB

KAESER

H 3 7 4 Air flow rate 0.58 to 248 m3/min

Contaminants:
KAESER rotary screw compressors *FE micro-filters + Solids –
Conveying air for waste water I 3 9 4 can be optionally
installed in TG to TI + Water/ Condensate –
Other machines series refrigeration + Oil –
No quality requirements J dryers.
8 9 5 + Bacteria –
For air mains subject to sub-zero temperatures: Compressed air treatment with a desiccant dryer (pressure dew point to -70 °C)
Degree of filtration:
Solids Water Oil Bacteria Upon
KAESER

Pure air and cleanroom < request Solid particles1) Humidity Total oil
Upon content
technology request 0 1-3 1
Class ISO 8573-1

Installation for heavily

Max.particle Max.particle Pressure dew
KAESER

Pharmaceutical industry, < < FST fluctuating air demand

dairies, breweries A 1 1-3 1 size concentration point point
KAESER

(x = liquid water
KAESER
KAESER

μm mg/m3 in g/m3) mg/m3

Microchip production, optics, food < <
KAESER

B
KAESER

and semi-luxury food production 1 1-3 1 FE FD ACT

KAESER

AMCS 0 e.g. Consult Kaeser regarding pure air and cleanroom

KAESER

KAESER

Filter technology
<
Paint spraying C 2 1-3 1 AMCS
Air receiver DD FE CS 1 0.1 0.1
Upon 2 1 1
KAESER

Pure air and cleanroom Upon < request

request 0 3 5 5
technology 1-3 1
KAESER

4 15 8
KAESER
KAESER

< < FST 5 40 10

KAESER

Process air, pharmaceutical A 1 1-3 1 6 – –

industry
7 – –
KAESER

< <
Photo labs B 1 1-3 1 Compressor THNF 8 – –
KAESER

KAESER

AMCS FG FD DD FE ED
9 – –
Especially dry conveying air, paint
spraying, fine pressure controllers F 2 1-3 1 Aquamat
1
) Particle load as per ISO 8573-1:1991
AMCS
A D H
E I
P-725ED.15/07 Specifications are subject to change without notice

B F J Untreated
C G

KAESER KOMPRESSOREN GmbH

P. O. Box 2143 – 96410 Coburg – GERMANY – Tel: +49 9561 640-0 – Fax: +49 9561 640130
www.kaeser.com – e-mail: productinfo@kaeser.com
Compressed air treatment

5.2.8 Pressure dew point after removal When compressed air relaxes (pressure released) the pres-
of pressure sure dew point drops. The following table is used to determine
the new pressure dew point and atmospheric dew point after
relaxation:

max. humidity [ g/m3 ]

]
op
ar-
[b
Pressure dew point [ °C ]

Example1
op
p
re
su
res
erp
Ov

Example 2

Atmospheric dew point [ °C ]

Example 1 Example 2

Compressed air Compressed air

– pop = 35 bar air pressure – pop = 7 bar air pressure
– Pressure dew point 10° C – Pressure dew point 20° C
relaxed compressed air relaxed compressed air
– pop = 4 bar air pressure – atmospheric air pressure pop = 0 bar
⇒ The new pressure dew point is approx. -23° C ⇒ The atmospheric dew point is approx. -8° C

76