Belts burning on a Kaeser Sigma 30hp rotary air compressor

by Jack Vines
(Spokane, WA, USA)

Kaeser Sigma air compressor

Kaeser Sigma air compressor

Our plant had a Kaeser Sigma 30hp rotary air compressor which burned up belts


Rather than troubleshoot, they just bought a new one. I got the used unit for hauling it away.

I'm hoping it is salvageable to use for a large-volume sandblasting project.

What gasoline engine horsepower would be required to replace the 30hp 3-phase electric motor?

Where do I start troubleshooting what caused the unit to lock up enough to burn off the belts? The compressor spins freely, so my first thought is pressure lockup somehow.

thanks in advance

jack vines

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Jun 25, 2014
Belts
by: Carls421

Have you checked the pulley alignment? Make sure the pulleys are level with each other, also check the belt tension is correct when youre putting new belts on, check youre using the correct belts too.
Are the pulley grooves ok and dont have slight nicks out of them, might be damaging your belts

Jun 24, 2014
Kaeser Sigma
by: Doug in s.d.ca

For starters, have you contacted kaeser?

Do you know the circumstances of the belt failure, like all of a sudden, over a period of days, or what?

30 horses is 30 horses, or a bit less than 22.4KW, but you'd have to provide engine control as well, which is not trivial.

I don't suppose you have 200A 3phase service, which is why you ask about the engine?

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critical error code 300A on Kaeser compressor

by Mark
(Baltimore Maryland)

Critical error code 300A on Kaeser compressor. What is this error code and what does it mean

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Feb 16, 2016
error message sigma controllers
by: Anonymous

the sigma controllers are notorious for the error message. we have seen probably about 10 controllers with the same error , it is a small relay on the controller that creates the message unfortunately kaeser in there wisdom do not have error on there machines so we are told.. LOL

Feb 20, 2015
Sigma Control
by: Anonymous

Just make sure when you get a new control module that it is actually set up to work when it is installed. I Bought a new one from an authorised Kaeser distributor under the understanding that it was set up and ready to go. We installed it but not only was the display in German (which I changed) But it needs a level 5 password to get it up and running. Not much chance of that as they want to send their service tech out and charge me about Eight hours travel time plus the service fee. In retrospect I should have scrapped the compressor and replaced it with something more user friendly.

May 14, 2014
Sigma
by: Carls421

Hi Ron,
Your only last hope is getting it whats called "K-loaded" by the manufacturer, this means the software totally wiped and put on again. I dont know how much that costs but the critical error can still reappear at some point so it a bit of a gamble. Id get in touch with your nearest HPC distributor to see what they will do for you, obviously they may just say buy a new one but ask about getting it K-loaded first. That really is your last option unfortunately.
Having a critical error is really quite rare like i said but it can happen very randomly. One of the 3 i have seen in the 20 years of working on air compressors, happened whilst i was servicing it. Trying to explain to the customer that it wasnt anything i had done was a nightmare! You are one of the unlucky ones im affraid to say. :-(
_______________
Carl, just another thank you from me for you taking the time to respond to Ron on this post. Your comments and advice are read by many, not just the one to whom you respond. Your information is valued and appreciated.

Bill

May 13, 2014
is replacing the ssigma control the only fix
by: Anonymous

Thanks for the information Carl. I'am in Southern California. There is nothing else that can be done to fix the sigma control besides replacing it?
Thanks again,
Ron

Mar 22, 2014
Critical Error
by: Carls421

Hi,
The Critical Error on the Kaesars Sigma controller means there is a software error on the actual controller, the compressor itself is all fine but your controller is no longer useable which means it needs replacing.

Sometimes you can turn the machine off at the main isolator for 5 minutes then switch back on again and it will work for anything between 5 minutes to a few weeks, but it will come back, so unfortunately it does need replacing.

Be warned, these are very expensive depending on which one you have (Sigma Basic is the cheapest, Sigma 1 most expensive) youre looking at between £800-£2000 for replacement.

But check with your local HPC supplier. Im in East Anglia in England. Where abouts are you?

Sorry for the bad news but hope that helps

Carl

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Does Kaeser SM-11 also require 120vac ?

by Fadi
(BLACKWOOD, NJ)

Hi ,I have bought a Kaeser compressor model: SM-11, about 3 years ago, I'm in the process of getting it on line.
I connected the high voltage 460vac, does this compressor also require 120vac ?

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Jun 20, 2014
SM-10?
by: Doug in s.d.ca

I don't see an sm-11...

On the sm-10 I see only a connection for three phase. Absent a connection for 120, I'd say no. It probably uses lower voltage on the control panel but it would normally be taken off the 3-phase.

Why do you ask? Do you have installation drawings/instructions? Does it not power up for you?

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compressor Kaeser DS-141 remains long in load

by Francisco Ramos
(San Cristobal, San Cristobal, Dominican Republic)

Kaeser DS-141 air compressor

Kaeser DS-141 air compressor

Sorry for the traduction, I speak Spanish.

unloading setpoint = 108 psi
loading setpoint = 90


When the compressor starts the first time the loading and unloading cycles lasting 5 min and 1 min respectively. As time passes the loading time it is becoming bigger all day and finally stays on. this is because the compressor reaches a state that does not have the ability to reach setpoint unloading. After that the pressure in the system falls slowly day by day.

When other compressor is turned on, this makes the loading and unloading cycles, but eventually the same thing happens as above.

Could be the air inlet temperature, or any mishandling system with respect to pressure.

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Jul 24, 2016
Air Comp
by: Anonymous

Check the air filter. If this Is blocked, it can cause the compressor the inability to build pressure.

Apr 27, 2014
More info?
by: Carls421

Hi,
A few questions about your system.
You say that the pressure drops as time goes on, and it seems the compressor is trying to get to pressure but cant? is this all of the time or just occasionally? What do you use your compressed air for? Have you recently added any new equipment to the air system?

From your description, a drop in pressure where the compressor cannot reach the unloading pressure, usually means there is too much air being used in the system that the compressor cannot keep up, but could you have a look at the pressure gauge inside the compressor which is attached to the seperator tank (where the oil goes), also the pressure reading on the compressor controller and the pressure gauge on your receiver. What are they reading at the point where the compressor is constantly on load?
When was your compressor last serviced?

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