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Kaeser SM11 Manual
Kaeser SM11 Manual
SERVICE MANUAL E
Screw Compressor
Model: SM 11/7,5 bar
GL-Nr.: BA-SM11.L-1.9B23.80100-00
Index: 000215
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Part No.:
Serial No.:
Manufacturer:
Table of Contents
Chapter - Page
I 1.9
1.10
Maintenance Interval for the Electric Motor .............................. . 1 - 3
Dimensional Drawing ................................................ . 1 - 3
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7 Initial Start .................................................... 7 - 18 10 Spare Parts and After Sales Service ... . . . . . . . . . . . . . . . . . . . . . . . . .. 10 - 46
7.1 Points to be Observed before Initial Start ................................ 7 - 18 10.1 Service parts and expendable parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10 - 46
7.2 Points to be Observed before Starting the Compressor Package: ........... 7 - 18 10.2 Service and Maintenance Agreement ................................... 10 - 47
7.3 Door Interlock Switch Check ........................................... 7 - 19
Direction of Rotation Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 21
11 Appendix ............................................ ·········· 11 - 48
7.4
7.5 Setting up the Motor Overload Trip ..................................... 7 - 21 11.1 Electrical Diag ram .................................................... 11 - 48
Setting the Air Main Pressure Threshold . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 21 11.2 Record of Maintenance Work 11 - 64
7.6
7.7 Measures to be taken before Initial Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 22
7.7.1 Pour a small quantity of oil into the air inlet port. . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 22
7.7.2 Running the compressor package in idle ................................ 7 - 22
7.8 Checklist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 7 - 23
8 Operation............................ . . . . . . . . . . . . . . . . . . . . . . . .. 8 - 24 ~
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9 Maintenance .................................................. 9 - 28
9.1 Observe the following during all Maintenance and Servicing Work .......... 9 - 28
9.2 Regular Maintenance ................................................. 9 - 29
9.3 . Opening and Closing the Compressor Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . .. 9 - 30
9.4 Checking the Tension of the V-belts .................................... 9 - 30
9.5 Changing the V belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 - 31
9.6 Cleaning or Renewing the Filter Mat .................................... 9 - 32
9.7 Cleaning or Renewing the Air Filter ..................................... 9 - 32
9.8 Servicing the Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9 - 33
9.9 Checking the Pressure Relief Valve on the Oil Separator Tank. . . . . . . . . . . . .. 9 - 33
9.10 Venting the Compressor Package ...................................... 9 - 34
9.11 Oil Filter Change ..................................................... 9 - 35
9.11.1 Removal and replacement of the oil filter ................................ 9 - 35
9.12 Oil Top Up ........................................................... 9 - 36
9.13 Cleaning the Oil Cooler and Air Cooler .................................. 9 - 38
9.13.1 Removing and cleaning the oil/air cooler ................................ 9 - 38
9.14 Oil Change (Oil Separator and Oil Cooler) ............................... 9 - 40
9.14.1 Draining the oil using external pressure source ........................ · .. 9 - 41
9.14.2 Adding oil ........................................................... 9 - 42
9.14.3 Draining the all using own compressed air ............................... 9 - 42
9.14.4 Measures for putting back into operation ................................ 9 - 43
9.15 Changing the Oil Separator Cartridge .............................. . . . .. 9 - 43 J'<,
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Technical Specification
It" Technical Specification
Measurement to CAGI/PNEUROP PN8 NTC 2.3: Exhaust air for solution B (see chapter 6.1):
Sound Pressure Level ................................. 69 dB (A) Exhaust air used for space heating:
Heating duct w x h . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 200 x 355 mm
1.3 Motor
1.7 Oil Capacities
Drive motor: Total oil capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .. 5 I
Rated power ........................................ 7,5 kW
1 After oil change or after long period of storage
Rated speed ....................................... 3600 min-
Amount required to top up the airend .................. 0,1 I
Protection class .................................... IP 54
V-belt set:
Par! number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6.2510.0
1- 2
1- 1
Technical Specification Technical Specification
2 Safety Regulations Valid national safety regulations must be complied with if the corresponding European
Standards are nor yet incorporated into national legislation.
Read this service manual carefully and observe cautionary references before putting this Users of compressor packages located outside the jurisdiction of European Standards are
compressor package into operation and before carrying out any maintenance. obliged to comply with the safety and accident prevention regulations concerning the com-
pressor package that are valid in the country of use. If necessary, corresponding measures
must be taken to ensure compliance with these national regulations before the compressor
2.1 Explanation of Symbols and References package is put into operation.
This symbol is placed before all references to safety where danger to We also recommend observation of the following:
life and limb can occur. It is especially important that these regulations
are observed and that extreme care is taken. For their own protection, • Allow no open flame and flying sparks in the place of installation.
all other users must be informed of these safety regulations. Observe
general safety and accident prevention regulations as well as the
• During any necessary welding on or near the compressor package ensure that sparks
or high temperatures cannot cause fire or explosion.
safety regulations laid down in this service manual.
• Ensure that clean air without damaging impurities is fed to the compressor package.
I Attention! I This symbol is placed by text where considerable attention must be "';i\
, } • Do not allow the maximum ambient temperature to be exceeded (see chapter 1.6),
otherwise special measures must be agreed between the manufacturer and the cus-
paid so that recommendations, regulations, references and correct se-
quence of work are adhered to and that damage andlor destruction of •• tomer.
the compressor package andlor other equipment is prevented.
• Carry out oil changes according to the service manual.
This symbol identifies environmental protection measures. • Do not mix oils of different types.
• This bullet identifies listings . • If maintenance work is carried out on any part of the oil circulation system, top up the
oil in the oil separator tank to the maximum level, run the compressor and keep it
under constant observation for a short period. Check the oil level again and top up
with oil to replace the oil taken up by the piping and the cooling system.
2.2 General Safety Instructions
• Change the filter cartridge in the oil separator tank as soon as the pressure drop
Work on power driven systems may only be carried out by trained or across the cartridge reaches 1 bar. Check constantly.
specialized personnel.
Work on electrical equipment in the compressor package may only be 2.3 Electrical Safety
carried out by a trained electrician or trained personnel under the The electrical installati~n of the compressor package must conform to the requirements of
supervision of a trained electrician according to electrical engineering European Standards EN 1012-1 and EN 60204-1. The regulations of the local electricity
regulations. authority must also be complied with.
Before work is carried out on electrical systems, carry out the follow- For this reason, the following measures must be carried out by the user to ensure the
ing measures in the sequence shown. safe operation of the compressor package:
• Compressor packages fitted with a drive motor of 3 kW or above and a current rating
1. Switch off the main switch of 16 amperes or above must be fitted with with a lockable main switch (see EN
60204-1, P 5.3) and mains fuses.
2. Ensure the main switch cannot be switched on again
• The type of main switch used is dependent on the power consumption of the drive
3. Check that no voltage is present motor (see chapter 1.4 for value).
• The type of protective circuit breaker used is dependent on the starting characteristic
Pipework under pressure should be vented or shut off if not stated
of the drive motor.
otherwise in the service manual.
• See chapter 1.4 for recommended cable cross-sections and fuses.
I Attention! I Any modification or conversion carried out without prior consultation
with KAESER and without KAESER's prior written consent will invali- 2.4 Spare Parts
date the warranty.
Original KAESER parts are designed and matched to meet the technical requirements of
Euro.pean Standards must be observed during installation, operation, maintenance and the air system. Only the use of original KAESER spare parts and KAESER SIGMA cooling
repair of the compressor package. , 1 oil guarantees safe and reliable operation.
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2-6
2-5
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Safety General
Ensure that all lubricants, consumable materials and replacement 3.2 Incorrect use
parts accumulating during operation and servicing of the compressor
package are disposed of according to environmental'regulations. Never direct compressed air toward persons. Compres~ed air is a con-
centrated form of energy and as such is dangerous to hfe.
The following points must be observed when handling lubricating and
cooling materials:
3.3 Compressed Air Treatment
Avoid contact with skin and eyes.
Never use compressed air from oil injected compressor ~ackag,:s for
Do not inhale vapours and oil mist.
Do not eat or drink when handling such materials. breathing purposes and production methods where the .alr has ~I~ect
contact with food, without subjecting the compressed air to additional
Fire, open flame and smoking are strictly forbidden.
treatment.
3.4 Copyright
All rights reserved.
No part of this publication may be reproduced or utilized in any form or by any mea~s~ ,
o electronic or mechanical, including photocopying and microfilm, Without prior permission In
writing from KAESER COMPRESSORS.
3-8
2-7
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Transport Construction and Operation
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min. 800mm
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Dispose of packaging according to environmental regulations and re- 5.3 Pipe and Instrument Flow Diagram (P & I Diagram)
cycle where possible.
(see following pages)
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5 - 10
4-9
Air inlet
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Air filter
2 Inlet valve
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Oil temperature controller
Oil fitter
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2.1 Oil filler w'lth plug
11 Oil cooler ::l
3 Drive motor CI
12 Minimum pressure check valve
4 Airend ::l
13 Air cooler C.
4.1
4.2
Strainer
Pressure switch - Wrong direction of rotation 16 Dirt trap
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17 Nozzle (1)
5.2
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6.1
PT100 sensor
Pressure gauge
18/19 Combined control/vent valve
18 Control valve
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19 Vent valve ::l
6.2 Hose coupling (oil end)
20 Shut-off valve - Vent line
6.3 Hose coupling (air endl
21 Silencer
6.6 Shut-off valve - Oil drain
59.1 Pressure measuring transducer Air main pressure
6.9 Oil level sight glass: minimum/maximum oil level
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Construction and Operation Construction and Operation
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Idle
.8 Idle ~ . Standstill
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Time .. I TIme I_
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In DUAL Control mode (combined idle and start-stop) the compressor normally runs at I I
full-load, idle or standstill. ~deCay
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The controller regulates the compressor package between load and idle. Running period • I I I
If the compressorpackag~ runs in idle for longer than the preset period (1) to (2), for Idlel I I I
ex~mple t1 = 6 min, the drive motor IS stopped completely (2). When the lower switching standstill period I I I
~olnt Pm!n (3) IS reached the compressor package is automatically started again. Pressure Run -on period I --+l+- --+l+- I
rises to the upper switching point Pmax (4), and the compressor package switches to idle. If
the pressure falls again to, for example, Pm!n (5) within a shorter period (4) to (5) then the
compressor is automatically switched from idle to load. ' Stop point for the running period or idle I standstill period
Pmax upper switching point
~rise
pressure rise time (the time during which the air main pressure rises
from the lower to the upper switching point)
ipdeCay
pressure decay time (the time during which the air main pressure decays
from the upper to the lower switching point)
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Functional description
Two fixed periods - the running period and idle/standstill period - are taken a~ the.crit-
erium for selection of the operating mode of the compressor package when the air main
pressure reaches the upper switching point. These two periods are set according to the
maximum permissible starting frequency of the drive motor.
The running period starts every time the compressor package is switched .on. It lasts as
long as the drive motor runs and stops when the compressor package sWitches to stand-
still.
The idle/standstill period starts every time the operating mode changes from full load to
idle. It runs during idle and also when the compressor package is switched to standstill
after the idle period. It stops when the compressor package switches to full load.
Every switching off point is delayed by the run-on period, during which time the com-
pressor package vents.
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5 -14 , .
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5 - 13
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Construction and Operation Installation
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Meas urements in mm
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Installation ·-1 -
I nitial Start
• Do not operate this compressor package in spaces where very dusty conditions, toxic
or inflammable gases could exist. ,I
IAttention! I ~he cross-section of the supply cable and the fuse ratings are speci- I,
fied to DIN VDE 0100 part 430 and 523 for an ambient temperature of • Do not connect the compressor package to a supply voltage other than that stated on
the nameplate.
30 'C. For other operating conditions, e.g. higher ambient tempera-
tures or longer supply lines (over 50 m) check and determine the
cross-section of the cable and the fuse ratings according to • Do not install the compressor package in a space subject to freezing temperatures.
The air temperature conditions at the air-intake must be complied with (see chapter
DIN VDE 0100 and local electricity authority regulations. 1.6).
See chapter 1.4 for recommended cable cross-sections and fuses. • If an exhaust air duct is installed, the cross section of the duct must be equal to or
larger than the cooling air outlet of the compressor package and may not exceed the
permitted pressure loss prescribed by the compressor manufacturer.
• During installation of the compressor package, ensure that a distance of at least 0.5 m
is kept between the air intake of the package and any wall.
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6 - 17 7 - 18
Initial Start Initial Start
0" Check the oil level in the oil separator tank (see chapter 9.12). Visual door interlock switch check
• Check that the air end rotates in the correct direction (see chapter 7.4). 0" Check that the interlock switch operates smoothly by opening and closing the left-
0" Check the tension olthe V-belts (see chapter 9.4). hand access door.
0" The shut-off valve (6.6, see chapter 5.3) must be closed. IAttention! I If the actuator (3) at the door interlock is incorrectly aligned, inadver-
tent shutdown of the compressor package can occur.
0" The shut-off valve (20, see chapter 5.3) must be open.
Carry out the following work only when power is removed from the The actuator (3) should align with the door interlock switch (1) without
compressor package. binding against the sides of the interlock switch when the access door
is closed. '
Check ali screws on the electrical connections for tightness (carry out
this check again after 50 operating hours). If necessary, re-align the actuator (3).
0" Loosen the bolts (4).
• This compressor package is fitted with a running -in oil filter. Replace the filter after the
0" Align the actuator (3) so that it glides smoothly into the interlock switch (1).
running-in period 01200 hours has elapsed (see chapter 9.11).
I]) 0" If necessary, use shims to help align the actuator (3) with the interlock switch (1). I
7.3 Door Interlock Switch Check 0" lighten the bolts (4) again. ,I.
I.
It is not permitted to operate the compressor package without a cor- I
rectly functioning door interlock switch.
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1 Door inter/ock switch
2 Clamping nut
3 Actuating element
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Bolt
Frame
Access door
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1 Door inter/ock switch Functional check of the interlock switch
I Attention! I A functional check of the door interlock switch must be made after in-
itial start.
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7 - 19 7 - 20
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Initial Start Initial Start
7.4 Direction of Rotation Check 7.7 Measures to be taken before Initial Start
IAttention! I The compressor package is wired for connection to a clockwise phase
sequence.
Take the following measures before initial start, after an oil change or a shutdown period of
three months or longer:
A check of the direction of rotation can be made by testing the phase sequence.
7.7.1 Pour a small quantity of oil into the air inlet port.
Arrows showing the direction of rotation are located on the motorand on the air end hous-
ing. Switch off and lock out the main switch.
If the direction of rotation is incorrect. change over the supply conductors L1 and L2.
I Attention! I If the air end rotates in the wrong direction, the compressor package is Do not add oil unless the compressor package is completely vented.
automatically shut down by the pressure switch (4.2, see chapter 5.3).
See chapter 9.10 to vent the compressor.
7.5 Setting up the Motor Overload Trip
Disconnect the supply voltage to the compressor package by switch-
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u Unscrew the filler plug (1) on the inlet valve (2) and pour the prescribed quantity of oil
(see chapter 1.7) into the airend.
ing off and locking out the main switch before any adjustments are I u Turn the airend counterclockwise by hand using the belt pulley.
carried out on the compressor package. See chapter 2.3 for the main
switch.
u Screw the plug back in again.
The trip is set to the standard adjustment at the factory. IAttention! I This oil must be of the same type as used to run the compressor {see
label near the oil filler plug on the oil separator tank}.
Compressor motor: star- delta start
If no additional oil is available then remove the required amount of oil
In the star-delta configuration the phase current is fed via the motor overload trip. This
from the oil separator tank. See chapter 9.14 for this procedure.
phase current is 0.58 times the rated motor current.
See motor nameplate for the rated motor current. If the compressor package was shut down for longer than 12 months,
Value: further measures must be taken before putting it back into operation.
Consult the manufacturer first.
To prevent the overload circuit breaker from triggering (because of voltage fluctuations,
temperature influences or component tolerances), the set value can be up to 15% higher u Open the shut-off valve between the compressor package and the air main.
than the arithmetical phase current.
1
1 Rller plug
2 2 Inlet valve
1 Motor phase current adjustment At initial start run the compressor package in idle for 20 seconds by pressing the load/idle
2 Reset button key (5, see chapter 8.3.1).
This measure ensures that the compressor package has sufficient time to flood the oil cir-
culation.
7.6 Setting the Air Main Pressure Threshold
The air main pressure threshold is preset at the factory. It can be changed in
SIGMA CONTROL to match customer's operational requirements if the password is known.
For further details, consult the SIGMA CONTROL service manual.
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7 - 21 7 -22
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o yes 0 no I
u Have all screws, bolts and electrical connections been checked for tightness?
1 SIGMA CONTROL
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o yes 0 no 2 EMERGENCY STOP pushbutton i
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u Has the oil level in the oil separator been checked?
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OyesOno 8.2 SIGMA controller I
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u Is a main switch fitted (suited to the motor starting characteristics)? The SIGMA controller (1) is fitted in the control cabinet in the compressor package and
o yes 0 no serves as the control panel. It has 11 keys and 9 LEDs. Operation of the compressor pack-
age is determined by the settings programmed into the controller.
u Has the setting of the drive motor overload current trip been checked?
Further details on individual function keys, LEDs and plain text display relating to possible
OyesO no alarms and service messages, display of events, etc. are given in the service manual sup-
u Have you ensured that there are no other air components located in the exhaust air flow plied for the SIGMA CONTROL controller.
of the compressor package?
o yes 0 no 8.3 Emergency Stop Pushbutton
u Have service personnel been instructed on safety regulations? The Emergency Stop pushbutton shuts down the compressor package immediately.
o yes 0 no If the Emergency Stop pushbutton is pressed because of an existing hazard, then this
must be eliminated before the compressor package is reset. To accomplish this the follow-
ing procedure must be carried out:
u Unlatch the Emergency Stop pushbutton by turning in the direction of the arrows.
u Acknowledge the alarm message on the controller by pressing the acknowledge
(reset) key. (function keys see chapter 8.3.1.)
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7 - 23 8 - 24
I Operation Operation
IAttention! I Do not switch the the compressor package on and off with the main
switch. The compressor must always be switched ON and OFF with
7
11 keys (1) and (2).
8
10 9 Local ON:
6
u Switch on the main switch.
1
The controller carries out a sell-test. The sell-test sequence is visible in the display (12).
5 2 Afterwards, the green LED (16) illuminates permanently.
u Press the ON key (1)- LED (19) illuminates. I
The compressor status is indicated by LEDs (17) and (18):
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4 3 I Attention! I If LED (19) is illuminated and both LEOs (17) and (18) are extinguished
1 ON key ("I"') 6 Menu scroll - DOVVN key
the compressor package is at standstill but on duty. II
2 OFF key ("0") 7 Menu scroll - UP key
3 TImer ON/OFF key 8 The compressor package can start at any moment. I,
Escape key ,
4 Remote ON key 9 Return key
5 Load/idle key 10 Info - event key Local OFF:
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11 Acknowledge (reset) key u Press the OFF key (2) - LED (19) extinguishes.
u Switch off and lock out the main switch.
8.3.2 Light emitting diodes and plain text display See chapter 2.3 lor details 01 the main switch. I
8.5 Acknowledgement of Alarms
13
II an alarm occurs the compressor package is shut down immediately and the red LED 'I
14 (13) on SIGMA CONTROL flashes. I
12
15 The bottom line in the display (12) shows the actual lault causing the alarm.
A list 01 alarms that may occur during operation is included in the SIGMA CONTROL I
16 19 service manual. !
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17 u Remove the lault.
18 I;J) () u Acknowledge alarm with the reset key (11) - LED (13) extinguishes. I!
The compressor package is now ready to start again.
20 21 I Attention! I If the compressor was shut down with the EMERGENCY STOP push-
button, then reset by rotating the latched pushbutton in the direction of
12 Four-line display 17 Load LED the arrow before acknowledging the alarm.
13 Alarm LED 18 Idle LED
14 Communication alarm LED 19 Compressor ON LED
15 Warning - maintenance LED 20 Remote ON LED
16 Power ON LED (to controller) 21 TImer ON LED
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8 - 25 8 -,26 'I!
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Operation Maintenance
I Atlention! I Before any maintenance is due an initial warning is displayed to allow 9.1 Observe the following during all Maintenance and Servicing Work
coordination of service and maintenance personnel and provision of
necessary servicing materials. (lubricants, spare parts, etc.). Work On power driven systems may only be carried out by trained or
specialized personnel.
Maintenance due is shown in the display (12).
A list of service messages that may occur during operation is included in the SIGMA Work on electrical equipment may only be carried out by a qualified
CONTROL service manual. electrician or trained personnel under the supervision of a qualified
P" Carry out the maintenance work. electrician according to electrical engineering regulations.
P" Acknowledge service message with the reset key (11) - LED (15) extinguishes. The compressor package restarts automatically after a power failure
(standard setting).
IAtlention! I When the respective maintenance has been carried out, the remaining Condition: the air main pressure is lower than the pressure set on the
interval period (programmed interval until the next maintenance is due)
must be reset.
o SIGMA CONTROL.
Switch off and lock out the main switch before attempting any mainten-
Detailed information on resetting service counters is to be found in the service manual for ance work (see chapter 2.3 for the main switch).
SIGMA CONTROL.
Ensure that no maintenance personnel are working on 'the compressor
package, that all panels are screwed back on again and that all access
doors are closed before starting the compressor.
I Attention! I The venting nozzle required to vent the oil separator tank (for mainten-
ance work such as topping up the oil, oil change and filter change) is
fitted to the hose coupling (3, see chapter 9.10).
Carry out a visual and functional check of the door interlock switch
after any maintenance and servicing work.
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8 - 27 9 - 28
Maintenance Maintenance
9.2 Regular Maintenance 9.3 Opening and Closing the Compressor Cabinet
24 h after initial start Check the tension of the V-belts It>" Open the access door (1).
9.4
It>" Pull the locking lever (3, photo A) outwards, turn 90' in the direction of the arrow and
50 h after initial start . Check all electrical connections for tightness latch onto the frame.
200 h after initial start Change the oil filter 9.11 It>" Lift the panel (2) and remove.
Weekly Check the oil level 9.12 To close:
Check the filter mats for clogging 9.6 It>" Turn the locking lever (3) to its initial position.
500 h Check the tension of the V-belts 9.4 It>" Attach the panel (2) making sure that it latches.
Clean the air filter' 9.7 It>" Close the access door (1).
1000 h Check the oil cooler and air cooler for clogging 9.13 Close all access doors and panels correctly before starting the com-
pressor package.
Clean or renew the filter mats' 9.6
• The maintenance period can vary depending on the motor switching frequency and
environmental conditions . o
•• Only applies to Sigma Fluid Plus (see label on oil separator). If other oils are used con-
tact an authorized KAESER service agency. National regulations concerning oil changes
must be strictly adhered to. 3
We urgently recommend that a record is kept of all servicing done (see chapter 11.2) and
1 Access door
that the compressor package - especially safety devices - are checked annually by an
2 Cover panel
authorized KAESER service agency. 3 Unlocking lever
Switch off and lock out the main switch to prevent accidents during
maintenance.
Check the tension of the V-belts after the first 24 hours of operation and then every
500 hours of operation.
\)
9 - 29 9 - 30
, ,I
~
Maintenance Maintenance
~~~+--2 D' Switch off the compressor package (see chapter 8.4).
1
Switch off and lock out the main switch to prevent an accidental com-
pressor run.
ol-c:--- 3
~--1
1 Hexagonal nut
2 Hexagonal nut Of)
3 Marking pin
'---- 2
The V-belt tension is automatically adjusted within a limited range by the pressure spring
of the belt tensioning device.
Re-tension the V-belts if they have stretched to the point where the marking pin (3) is
located at the top end of its indicator slot.
D' Loosen the hex nut (2).
1 Riter mat
OJ Re-tension the V-belts with the hex nut (1) until the marking pin (3) is located at the 2 Holding frame
bottom end of its slot.
D' Remove the holding frame.
D' lighten the hex nut (2).
D' Open and close with a screwdriver.
9.5 Changing the V belts D' The clamping frame sits securely after turning the snap fasteners by a 14 turn.
D' Switch off the compressor package (see chapter 8.4). Cleaning:
Rinse the mat in water of approximately 40°C, if necessary with a mild washing powder.
Switch off and lock out the main switch to prevent accidents during The mat can also be tapped with the palm of the hand, cleaned with a vacuum cleaner or
maintenance.
D' Loosen the hex nut of the swing frame adjustment (2, see chapter 9.4)
u blown out with compressed air. Rinse out oily dust with warm water using a mild solvent
additive.
D' Screw the hex nut (1, see chapter 9.4) until the V-belts are loose. I Attention! I If the mat is heavily soiled or has been cleaned often (max. 5 times),
replace it.
D' Remove the V-belts.
I Attentionl I It is essential that replacement belts are all precisely the same length
9.7 Cleaning or Renewing the Air Filter
(each set) and absolutely oil- proof. For this reason we recommend
that only original KAESER drive belts are used. Clean the air filter after every 500 service hours.
[>" Place the new V-belts over the motor and compressor pulleys without straining them. D' Stop the compressor unit (see chapter B.4).
D' Set the V-belt tension (see chapter 9.4). Switch off and lock out the main switch to prevent an accidental com-
pressor run.
I Attentionl I Check the V-belt tension after two hours of operation and then again
after 24 hours of operation, as experience shows that the belts stretch
mostly during this period.
9 - 31 9 - 32
Maintenance Maintenance
Switch off and lock out the main switch to prevent an accidental com-
pressor run.
[7 Close the shut-off valve between the compressor package and the air main.
The oil circulation vents automatically.
IAttention! I Do not clean the air filter cartridge with fluids. If the air filter cartridge
is heavily contaminated or was already cleaned several times (max.
5
five times). renew. ,
.1
To close the filter housing: 9
[7 Insert the filter cartridge (4) and replace the air filter cap (2).
[7 Screw on the wing nut (3) tightly. 7
9 - 33 9 - 34
! i
Maintenance Maintenance
Venting the air-cooler: u Spin off the used or contaminated oil filter counter-clockwise and catch escaping oil
in a suitable container.
When the compressor package is vented, the air-cooler and the pipe-
work up to the minimum pressure check valve are still under pressure. Dispose of the used filter and used oil carefully according to environ-
For this reason the compressor package must be isolated from the air mental regulations.
main (close the user's shut-off valve). If a shut-off valve is not avail-
able, vent the air main completely. u Clean the sealing faces carefully with lint free cloth.
u Lightly oil the gasket of the new oil filter before screwing into position.
u Carefully remove the pipe fitting (4, see chapter 9.13). The air-cooler vents.
u Spin on the new oil filter ,clockwise by hand until the gasket fits tightly.
u TIghten the pipe fitting again.
Close all access doors and panels correctly before starting the com-
IAtlention! I Do not use a tool as this may cause damage to the oii filter and the
gasket.
pressor package.
u Check the oil level (see chapter 9.12).
u Open the shut-off valve between the compressor package and the air main.
9.11 Oil Filter Change o
Carry out a trial run.
Hot oil; beware of scalding.
When the operating temperature is reached (see chapter 1.1) shut
During the running in period. a running-in oil filter cartridge is fitted to clean the oil sys- down the compressor package (see chapter 8.4) and lock out the main
tem. . switch to prevent an accidental compressor run.
I Atlention! I Replace the running - in oil filter cartridge with a standard oil filter car- Carry out a visual check for leaks.
tridge after approximately 200 operating hours.
A further filter change is recommended after the interval quoted in the regular maintenance 9.12 Oil Top Up
table (see chapter 9.2) or when the corresponding service message is displayed on SIGMA
Check the oil level weekly with the oil level sight gauge when the compressor unit is shut
CONTROL (see chapter 8.1). The filter must be changed after every oil change.
down. If necessary, top up the oil to the maximum level. To do this, it is imperative that the
compressor unit is switched off under full load conditions and that the oil level is allowed to
9.11.1 Removal and replacement of the oil filter settle for five minutes. Do not exceed the maximum level.
u Shut down the compressor package under full load (see chapter 8.4). u Shut down the compressor package under full load (see chapter 8.4).
Switch off and lock out the main switch to prevent an accidental com- Switch off and lock out the main switch to prevent an accidental com-
pressor run. pressor run.
o
Before opening or removing pressurized components (pipes, hoses,
Before opening or removing pressurized components (pipes, hoses,
tanks, etc.) it is imperative that the compressor package is completely
tanks, etc.) it is imperative that the compressor package is completely
depressurized.
depressurized.
u Venting the compressor package (see chapter 9.10).
u Venting the compressor package (see chapter 9.10).
9 - 35 9 - 3(3
-,-, --
Maintenance Maintenance
9 1
7 Ilfli'IIil!---=-~ 1
-Ic--- 10 =
~---2
8
3
4 -_-./'
I
1 Shut - off valve 4 Filler plug 8 Screwed sealing plug II
A shut (oil top - up) (oil cooler)
Bopen 5 Oil separator tank 9 Shut-off valve - oil drain
.2 Pressure gauge 6 Plug - in nipple 10 Hose coupling
3 Hose coupling 7 Oil level mini -Imaximum 11 External pressurization
1 Allen screw i
u Unscrew the oil filler plug (4) on the oil separator tank. I
L;' ()
2 Hose screw fitting I!I!
u Top up the oil to the maximum mark. 3 Pipe screw fitting
u Check the sealing ring of the filler plug (4) for damage and then replace the filler 4 Pipe screw fitting
plug (4). u Unscrew the hose connector (2) and the pipe connector (3) from the combination
u Open the shut-off valve between the compressor package and the air main. valve.
I Attentionl I After carrying out the oil change or oil cooler cleaning (with removal of u Unscrew the hex socket head screws (1) on the air cooler.
the oil cooler) run the compressor package up to operating tempera- u Remove and check the O-ring on the air cooler.
ture to ensure that the combination valve closes and that the oil cooler
is flooded with oil. u Close up the pipes and openings on the combination valve and air cooler.
If the type of oil is changed, drain the old oil completely and renew the '.'
oil filter.
9 - 37 9 -38
Maintenance Maintenance
The oil change interval is dependent on the degree 01 cooling air contamination and on the
ambient temperature.
II the compressor package is operated close to the maximum permissible ambient tem-
perature (see chapter 1.6), the oil must be changed more often, il necessary, the interval
should be halved.
See regular maintenance table (chapter 9.2) lor oil change interval.
6 I Attention! I Drain the oil out of the separator tank, cooler and the pipework com-
pletely. See chapter 9.14.4 for putting back into operation.
5 Hexagonal nut
6 Nlen screw 07 Shut down the compressor package under lull load (see chapter 8.4).
07 Unscrew the hex bolt (5). Switch off and lock out the main switch to prevent an accidental com-
pressor run.
The hex socket head bolts (6) are located behind two protective caps.
I Attention! I Before unscrewing the two hex socket head bolts (6) prop up the airl
2
11
oil cooler.
6
07 Remove the protective caps and unscrew the two hex socket head bolls (6).
07 Take out the airloil cooler. 3
Do not direct compressed air, water or steam jets at persons. These 4
jets represent contained energy and as such are dangerous to lifel
1
Clean the soiled cooler with water or steam jet in washing areas that
that are suitable for such cleaning work and provided with an oil sep-
arator! A F~
07 Clean the cooler cells with compressed air, water or steam jet.
LI U B~~~
07 Reassemble in the reverse order.
5
IAttentionl I Seat the 0 rings correctly in the compressed air inlet of the air cooler
during reassembly.
07 Open the shut -off valve between the compressor package and the air main. 7 I,
I
Carry out a trial run. 10
"
9 - 40 ,'
..
9 - 39 ,
II
r >,
Maintenance Maintenance
Before opening or removing pressurized components (pipes, hoses, 9.14.2 Adding oil
tanks, etc.) it is imperative that the compressor package is completely u Unscrew the oil filler plug (4) on the oil separator tank.
depressurized.
10" Venting the compressor package (see chapter 9.10). IAttention! I Always use the same brand and type of oil when topping up the oil.
(see label on the oil separator tank).
9.14.1 Draining the oil using external pressure source If a different type of oil is used drain the old oil completely and always
renew the oil filter.
10" Close the shut-off valve (1).
10" Insert the nipple (6) in the hose coupling (3) on the oil separator tank (5). Never mix different types of oil.
10" Apply external pressure source to the nipple until the pressure gauge (2) on the oil
u Top up the oil to the maximum mark.
separator tank (5) indicates approximately 3 bar.
For oil quantity see chapter 1.7.
10" Remove the nipple (6) from the hose coupling (3) on the oil separator tank (5).
10" Check the sealing ring on the oil filler plug (4) for damage and then screw in the oil
Draining the oil at the oil separator tank: filler plug.
10" Prepare a container to catch escaping oil.
9.14.3 Draining the oil using own compressed air
I Attention! I The container must be large enough to hold the total oil content of the
u Shut down the compressor package under full load (see chapter 8.4).
compressor package (see chapter 1.7).
Switch off and lock out the main switch to prevent an accidental com-
10" Hang the oil drain hose (10) in the canister and secure.
pressor run.
10" Slowly open the shut -off valve (9) (the remaining pressure in the oil circuit forces out
the oil). Close the shut -off valve (9) immediately when flir escapes. u Close the shut-off valve between the compressor package and the air main.
Before opening or removing pressurized components (pipes, hoses, The compressor oil circulation vents automatically.
tanks, etc.) it is imperative that the compressor package is completely u The pressure gauge on the oil separator tank must indicate zero bar.
depressurized.
10" Close the shut-off valve (1).
10" Venting the compressor package (see chapter 9.10).
Close all access doors and panels correctly before starting the com-
Drain the oil from the oil cooler: pressor package.
10" Prepare an oil container to catch the oil. u Start the compressor package (see chapter 8.4) and allow to run for approximately 30
10" Slowly unscrew the oil drain plug (1). The oil drains out under the force of gravity. seconds.
10" Screw the oil drain plug (1) back in tightly. ,\ )\ 10" Shut down the compressor package under full load (see chapter 8.4).
Dispose of the old oil according to environmental regulations. Switch off and lock out the main switch to prevent an accidental com-
pressor run.
u Check the actual pressure on the pressure gauge (2). Open the shut-off valve (1), let
the pressure on the pressure gauge (2) sink to approximately 3 bar and then close the
shut-off valve (1) again.
u Drain the oil from the oil separator tank and the oil cooler. Proceed as detailed in chap-
ter9.14.1.
u Open the shut-off valve (1).
u Top up with oil as described in chapter 9.14.2.
9 - 42
9 - 41
,
, I'
'
:I
!
Maintenance
Maintenance
i ,
o:r Top up with oil, see chapter 9.14.2. 4
, '
o:r Open the shut-off valve between the compressor package and the air main. 5 .--9
I I
o:r Switch on the compressor package, see chapter 8.4, and allow to run until the operat- 7
ing temperature is reached, see chapter 1.1.
o:r Top up the oil again, see chapter 9.12. 1
13
Carry out a trial run. !)
When the operating temperature is reached (see chapter 1.1) shut 11
down the compressor package (see chapter 8.4) and lock out the main
switch to prevent an accidental compressor run. 12
Carry out a visual check for leaks. 5 10
9.15 Changing the Oil Separator Cartridge 1 Spring 6 a-Ring (dia.BOxB) 11 Dir1 trap screen filter
2 Hose coupling 7 Groove 12 Bbow fitting
The service life of the oil separator cartridge is strongly influenced by the degree of conta-
3 Pressure gauge B Oil separating car1ridge 13 Contro/line
mination of inlet air and on strict adherence to the recommended maintenance intervals of
the air and oil filters. 4 Hexagonal nut 9 a-Ring (dia.80x3,5)
5 Cover 10 Groove
We recommend that the oil separator cartridge is changed with the oil or when the relevant
service message is displayed on SIGMA CONTROL (see chapter 8.1).
Earthing the oil separator cartridge is by means of a spring, inset and
'o:r Shut down the compressor package under full load (see chapter 8.4), clamped in the separator cover (5).
Switch off and lock out the main switch to prevent an accidental com- Care must be taken when changing the separator cartridge, not to
pressor run. damage this spring as earthing can only be ensured when it is in per-
fect condition.
Before opening or removing pressurized components (pipes, hoses,
tanks, etc.) it is imperative that the compressor package is completely o:r Unscrew the hexagonal bolts (4) and remove the cover plate (5).
depressurized. o:r Take out the old oil separator cartridge (8) with the 0 ring (6) and 0 ring (9) and dis-
pose of according to environmental regulations.
o:r Venting the compressor package (see chapter 9.10).
o:r Clean the sealing surfaces of the oil separator tank.
o:r Insert the new 0 ring (9) into the groove (10) in the oil separator tank.
o:r Insert the new oil separator cartridge (8) and then insert the new 0 ring (6) into the
groove (7).
o:r Fit the cover plate (5) and tighten down with the hexagonal bolts (4).
o:r Unscrew the union nut of the elbow fitting (12) and pull out the control air pipe (13).
o:r Unscrew and remove the elbow fitting (12) from the oil separator tank together with
the dirt trap screen filter (11).
o:r Replace the old dirt trap screen filter with a new one.
9 - 43 9 - 44
Maintenance Spare Parts and After Sales Service
117 Wrap teflon tape around the outside thread of the elbow fitting (12) and screw back 10 Spare Parts and After Sales Service
into the oil separator tank.
117 Insert the control air pipe (13) into the elbow fitting (12) and tighten up the union nut.
117 Open the shut-off valve between the compressor package and the air main. 10.1 Service parts and expendable parts
Carry out a trial run. No. off Order No.
Description
When the operating temperature is reached (see chapter 1.1) shut Oil filter 1 6.1876.1
down the compressor package (see chapter 8.4) and lock out the main (Operating temperature <ga°C) <
Comprising:
Separating cartridge
o Ring
1
2
,i
.1
Dirt trap screen filter 1 ,,[
Hose pipe from the minimum
pressure check valve to the
1 8.1190.1
II,I
air/oil cooler I
I
Hose pipe from the air/oil 1 8.1181.0
cooler to the compressor air
end
I~.~lia.~~d
D-'36~1O Coburg, Postfach 2143
L} ) Germany, Tel.: (09561) 640-0
Fm(.: 109561) 640-130
«(:
IModel I I
I Port No. I I
I Serial No. I I
I Year I I
IRated power I kWI
IRated motor speed I mln·11
9 - 45 10 --46
l'---
''/\
~
""
~ J.
Spare Parts and After Sales Service Appendix
<._
",-
11 -A8
10 - 47
~--
- - -- ....
- .-.-.. ~
1 2 I 1 4 5 6 I J e
Electrical diagrams
Compressor SM 11
440-460-480V SO/60Hz
,
b
,
Datum 29.05.2000
Bearb. Oberender
Gepr. Fischer
E
KAESER
KOMPRESSOREN
Cover page
Compressor SM 11
.
A Anderung
,=
Oatum Name
"". Ersah durch, Ersah fUr: Ursprung, AMS010S1.00 Sigma Control T DSM11-01021.00 Blatt 1
Bl.
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N,. Name Dra .... ing No. (customer) Drawing No. (manufacturer! Page Unit designation
,
6 Circuit diagram
Circuit diagram
Power supply unit
motne:r board/Inputs
SSMll-01021.00
SSM11-01021.00
l
4
e Circuit diagram mother board/Inputs SSM11-01021.00 5
9
10
Circuit diagram
CirCuit diagram
mothe:r board/Inputs
mother beard/Outputs
SSM11·01021.0Q
SSMll-0l021.00 ,
6
Compressor SM 11
.__ ___
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-- - --- --- --- --- --- -- - ---- ,- --EI ---
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--- --and- outputs
-- - - ---
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PE 0---- -----;
:~ Adapter 1
[QGJ
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lX32
lliIl ~ @DJ ~ ~
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4
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EMERGENCY STOF 1-
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activation
Compressor motor L ____________
1 lX2
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WB7
7 1\
--- -- - -- -- -- - -- - --- ----------
W19
activation
(ompressor motor
,1
L_. _____ _~___ _ ___ _ _ _ _ _ __ _ _ _ __ __ _ _ _ USl:lr's connection
--- --- ---- -- --- -- -. --- -- -___________________ -.J
M
3-
Compressor motor
l
~
b
\ IDitom 129.05.2000
8earb. Oberender KAESER Block diagram
a I
C Anderung
I
Datum
I IGe~r. I
Name Norm
FisCber
Er5at~ dun:h, Ersatz fur,
KOMPRESSOREN
Ursprung, AM5010S1,QO
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USM11-01021.00 ~
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1 1 1
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1 1 1
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1 , , AHENTiON !!1
Control transformer connections for
Lll2l3PE
440-460-480V/3/PE/50/60Hz 41,.0V: 440 and 0
See service manual for 460V: 1,.40 and .ZOV
supply cable cross-section 480V: 500 and -lOV
• Ll -X11_, -Xll.,
LO'. /~
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ATTENTION !!!
nov
[Imtrol transformer connedions tor connedion
s,b.c,
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10VA
460V: 440 and .. lOV
48DV; 500 and -lOY
-xll1:E
L -_ _ _ _ _ _ _ _ _ _ _ _ ~
,
-X11,\, N01 /3.1
Secondary side is earthed.
• If the shorting link
is removed, insul .. tion
monitoring must be
installed
EN 60204-1
"
I Name I Norm Ersatz durch, Er$~tz f.Qr, Ursprung, AMS010StOO Con~rol vol~age ~appiug
1 SSMll-01021.00
.,
B!<Jtt 2
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j
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24V DC lL .. IS.l
24V DC 2L .. IS.l
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-2X20 )9
-2X020 9
-Gl '.
-A 10.0 0
b- 81 188D
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0
230V- • 0
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24V= 0
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short tiHuit prQ~f
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-lX8 RS 232 -lX7
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2M 11.1
Fun,tlcn: 24V DC
Group of f~netlons, (ontrol vOltage tapping T Adapter 1
, Datu.. 29.05 ... 000 Circuit diagram
B~arb. Oberender
KAESER Compressor SM 11
,b KOMPRESSOREN
o Anderung Datum N~l1Ie
Gepr. fischer
Norm Er5atz durch, Ersatz fun Ursprung, AMS010StDO Power supply uni~ I SSMll-0l021.00 ~BI.
-.-_._-_.- -------.
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, I l I 4 5 ,
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PT laO H
12 11 PE
ct::1J ct -----------t)
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-2X041A,' A,' -2X043 AI' -2X043 At
-2X41 , , -2X43 , -2X43 , t
-2Xl A" -2Xl "" -2Xl A" -2Xl "''' -2Xl ",10 -2Xl A" -2Xl All -2Xl "'" -2Xl ",24 -2Xl "'" -2Xl ""5 -2Xll,
AI 1 AI 2 AI 3 AI 4
I Fu~tlion,
IGroup of fun~tion~, Pressure control
Datul Circuit diagram
Searb. KAESER
---- _.-
. [omoresc:.nr ,M 11
I <; <;M"_0 1021.0 0
4 _J , I
£/6.1
/3.B .1!:..:.
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-2X3! 5 -2X32
-2X032 ~l
-2X31 .'
-2X03 Ys -2X031r
-
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2X31
-2X20 l' -2X32l'
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1_ _ ~ _ _ _ _ _ _ _ ~ ________or~ _ _ _ _ _ _ _DI: _ _ _ _ _ _ _D~5_- _ _ _ _ _ ~_'_,
10.0 10.1 10.2 1003 10.4 10.5
mother board -Al0.3 /6.2
Inputs I 0.0 EMERGENCY STOP pushbutton I 0.3 Direction of rotation
I 0.1 Door safety interlock switch I 0.4
I 0.2 Compressor motor overload protection I 0.5
function:
Grou~ of functions, Alarm/maintenance indications
Circuit diagram
Datu..
S~~rb.
29.D5.2000
Oberender
KAESER Compressor SM 11
KOMPRESSOREN Blatt 5
o Ander~nq Datum Name
Gepr.
Norm
Finher
Ersatz dureh: Er5atz lur: Ur$~rung, AMS010S1.CO mother board/Inputs 1 SSM11-01021.00 BI.
-~,'
·I
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4 6
II"
/S.6 2L· 2l .. 17.1
-
-2X35 12
-K1M
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14
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-2X1 1 14
-2X20 l
-2X1 15
-2X20 4
-2X1 1 "
-2X35
-2X1
1 -2X20 5 -2X20 ,
" -2X1 1B
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-2X1 19
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10.6 10.7 11.0 11.1 11.2 11.3
Funetiol'l'.
Group Df funtlions: ~ indications
----',
4 6
-A10,4 ,'------------------------------------------------------------------------------------------,
I -1X311 14 12 13
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Cut-out Control secondary Compressor motor overload protection
Shutdown function
-Gl Power unit -82 Direction of rotation pressure switch
and
-K1M Mains contactor -Bll Temperature probe
Indicating function
-K2M Oelta contactor Airend discharge temperature
-K3M Star contactor
-Ml Compressor motor
-81 Pressure transducer, } Indicating function
-00 Overload protection switch,
Air main pressure
(ontro! transformer
-53 EMERGENCY STOP pushbutton
-510 Door safety interlock switch
Datum 29.05.2000
Searb. Oberender KAESER Ele[trical equipment identification
r,
•EIAnderung Gepr • Fischer KOMPRESSOREN Compressor SM 11
Datum Name NDrm I Ersatz durch, I Ersatz fUr: Ursprung, AMS01051.CO
1 55M11-01021.00 Blatt 9
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Oestination Oestination
(able identification Terminal strip (able identification
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