Professional Documents
Culture Documents
Screw Compressor
Model: ASD T Dual Voltage
No.: 9_5721_02USE
Contents
Chapter --- page
-------------
1
1
1
1
1
2
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Free air delivery (FAD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor and Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor motor: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Oil Volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power supply specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Heat Recovery (option W2 / W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
-----------------------------------
3
4
4
4
4
5
5
5
5
5
6
6
7
7
7
8
10
1
1
1
1
1
1
Correct Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Incorrect Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Users Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger from electric current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger from released spring force . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Danger from released compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Further dangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Emergencies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire supression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
---------------------------------
11
11
11
12
12
12
12
13
13
13
14
14
14
14
14
15
Contents
Chapter --- page
4.1.1
4.1.2
4.2
4.2.1
4.2.2
4.2.3
4.2.4
4.3
4.3.1
4.3.2
4.3.3
4.3.4
4.3.5
4.4
4.5
16
16
19
19
19
19
19
20
20
20
20
21
21
21
22
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Place of installation and space required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating in a compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
5
5
5
-----------
24
24
24
25
25
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Report Transport Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install the Compressed Air Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing main voltage connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condensate Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat recovery system connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
6
6
6
6
6
6
6
6
-------------------
26
26
26
27
27
31
31
31
31
-------------------------------
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 26
6.1
6.2
6.3
6.4
6.4.1
6.5
6.6
6.6.1
6.6.2
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine mountings (option H1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter mat panels (option K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Heat recovery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optional filter monitoring set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating States and Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Modulating control (option C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer control modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGMA CONTROL Keys and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
7
7
7
7
7
-----------------
33
33
33
34
34
35
35
36
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 37
8.1
ii
Contents
Chapter --- page
8.1.1
8.1.2
8.1.3
8.2
8.3
8.4
8.5
8.5.1
8.5.2
Switching on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Automatic restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching Off in an Emergency and Switching On Again . . . . . . . . . . . . . . . . .
Remote On and Off Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Switching on and off with the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Acknowledging and Resetting Warning and Alarm Messages . . . . . . . . . . . . .
Resetting alarm messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
8
8
8
8
8
8
8
-------------------
37
37
38
38
38
39
39
39
40
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 51
10.1
10.2
10.2.1
10.2.2
10.2.3
10.2.4
10.3
10.3.1
10.3.2
10.4
10.5
10.6
10.7
10.8
10.9
10.10
10.10.1
10.10.2
10.11
10.12
10.13
10.14
10.15
10.15.1
10.15.2
10.15.3
10.16
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Resetting maintenance interval counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling oil changing intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooler Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Air cooling (option K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter mat maintenance (option K3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Internal Heat Recovery Maintenance (option W2 / W3) . . . . . . . . . . . . . . . . . . .
Air Filter Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Filter mat maintenance (control cabinet) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electric Motor Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Venting the Machine Manually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking and Topping up the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check cooling oil level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Topping up the cooling oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Cooling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil filter maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Safety Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the refrigerant condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing condensate drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the condensate drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Logging Maintenance Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
10
-------------------------------------------------------
51
52
52
53
54
54
55
55
55
56
57
58
59
59
60
61
61
62
64
67
68
68
70
70
70
71
73
iii
Contents
Chapter --- page
11.2
11.3
11.4
11.5
11
11
11
11
---------
74
74
74
74
De---commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Packing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
12
12
12
12
-----------
81
81
81
82
82
13 Annex . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 --- 84
13.1
13.2
13.2.1
13.2.2
13.2.3
13.2.4
Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagrams and Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pipeline and instrument flow diagram (P&I diagrams) . . . . . . . . . . . . . . . . . . . .
Pipeline and instrument flow diagram (option C1) . . . . . . . . . . . . . . . . . . . . . . .
Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
13
13
13
13
13
-------------
84
84
84
90
96
99
iv
Directory of Illustrations
Chapter --- page
Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28
Fig. 29
Fig. 30
Fig. 31
Fig. 32
Fig. 33
Fig. 34
Fig. 35
Fig. 36
Fig. 37
Fig. 38
Fig. 39
Fig. 40
Fig. 41
Fig. 42
2 --- 7
2 --- 7
4 --- 16
4 --- 17
4 --- 18
4 --- 19
4 --- 19
4 --- 19
4 --- 22
4 --- 23
5 --- 24
6 --- 26
6 --- 27
6 --- 28
6 --- 28
6 --- 29
6 --- 30
6 --- 30
6 --- 31
6 --- 32
7 --- 34
7 --- 35
8 --- 37
8 --- 38
8 --- 39
10 --- 55
10 --- 56
10 --- 57
10 --- 58
10 --- 59
10 --- 61
10 --- 62
10 --- 63
10 --- 64
10 --- 66
10 --- 67
10 --- 69
10 --- 70
10 --- 71
10 --- 72
12 --- 82
12 --- 82
Table Directory
Chapter --- page
Tab. 1
Tab. 2
Tab. 3
Tab. 4
Tab. 5
Tab. 6
Tab. 7
Tab. 8
Tab. 9
Tab. 10
Tab. 11
Tab. 12
Tab. 13
Tab. 14
Tab. 15
Tab. 16
Tab. 17
Tab. 18
Tab. 19
Tab. 20
Tab. 21
Tab. 22
Tab. 23
Tab. 24
Tab. 25
Tab. 26
Tab. 27
Tab. 28
Tab. 29
Tab. 30
Tab. 31
Tab. 32
Tab. 33
Tab. 34
Tab. 35
Tab. 35
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitiy at rated pressure [CFM FAD] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor motor data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor motor rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan motor data (option K1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling oil volumes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply 230V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Supply 460V/3/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Quality Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General specification of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow rate and heat available (option W2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow rate and heat available (option W3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer, compressed air system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration dryer, refrigeration system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGMA CONTROL keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SIGMA CONTROL indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overview of ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload protection relay settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor protection switch settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checklist, installation conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Alarm messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warning messages and actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Miscellaneous events (faults) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular maintenance work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil change intervals lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Oil change intervals speciality lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regular service work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Machine maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 --- 3
2 --- 3
2 --- 3
2 --- 4
2 --- 4
2 --- 4
2 --- 4
2 --- 5
2 --- 5
2 --- 5
2 --- 5
2 --- 7
2 --- 8
2 --- 8
2 --- 9
2 --- 9
2 --- 9
2 --- 9
2 --- 10
2 --- 10
2 --- 10
4 --- 23
4 --- 23
5 --- 25
6 --- 28
6 --- 29
7 --- 33
9 --- 45
9 --- 49
9 --- 50
10 --- 53
10 --- 54
10 --- 54
10 --- 54
10 --- 73
11 --- 74
vi
1.1
1.2
Further Documents
Included with this Service Manual are documents intended to assist in safe and sure operation of the machine:
1.3
Copyright
This service manual is copyright protected. Inquiries regarding use or duplication of the
documentation should be referred to KAESER.
1.4
1.4.1
Warning notices
Here is a notice warning of danger.
DANGER
Danger levels
Warning notices indicate three levels of danger identified by the signal word under the danger symbol.
Signal word
DANGER
WARNING
CAUTION
Meaning
Warns of imminent threatening danger
Warns of possible threatening danger
Warns of a possibly
dangerous situation
1 --- 1
1 --- 2
Technical Specification
2
Technical Specification
Model and important technical information is to be found on the machine nameplate. The
nameplate is found inside the machine. It is fixed to the outside of the control cabinet.
Please transfer data from the nameplate.
Model
Part no.
Year
Serial no.
psig
cfm
Voltage
Hz/RPM
Package FLA
Phase
HP
Wiring Diagram
FOR SERVICE, REFER TO EQIPMENT
NUMBER
Tab. 1
Nameplate
A summary of the included options helps to relate the service manual information to your
machine.
Please enter details of options.
Code
K1
K3
H1
W1
W2
W3
C1
C2
T2
Option
Air cooled
Fillter mat panels
Machine mountings
Prepared for heat recovery
Internal heat recovery T= 25K
Internal heat recovery T= 55K
Modulation control
Optional filter monitoring package
Transformer power supply for refrigeration
dryer
Tab. 2
Options
2.1
Existing
Weight
Maximum weights are shown. Actual weights of individual machines are dependent on
equipment fitted.
ASD 25
3640
Weight [lb]
Tab. 3
ASD 30
4040
ASD 40S
4080
ASD 40
4320
Weight
2 --- 3
Technical Specification
2.2
Temperature
ASD 25
Minimum cut ---in tempera40
ture [ F]
Typical airend discharge
167 --- 200
temperature during operation [ F]
Max. airend discharge
230
temp. (automatic shut --down) [ F]
Tab. 4
Machine temperatures
2.3
ASD 30
40
ASD 40S
40
ASD 40
40
230
230
230
ASD 30
3000
40 115
40 115
ASD 40S
3000
40 115
40 115
ASD 40
3000
40 115
40 115
Ambient Conditions
ASD 25
3000
40 115
40 115
2.4
100
50
Pressure
See nameplate for maximum working pressure.
Maximum working pressure [psig]
ASD 30
155
230
230
ASD 40S
155
230
230
ASD 40
155
230
230
ASD 40S
166
166
132
129
112
110
ASD 40
191
191
163
159
127
125
Tab. 6
2.5
ASD 25
125
155
175
230
217
230
Safety relief valve setting
2 --- 4
Technical Specification
2.6
Sound Level
Operational state
under load at rated speed, rated delivery and rated pressure.
Measuring conditions:
Free---field measurement to CAGI/PNEUROP PN8 NTC 2.3 at 1 m distance
ASD 25
Sound level [dB(A)]
66
Tab. 8
Sound Pressure Level
2.7
2.7.1
Compressor motor:
ASD 25
Rated power [HP]
25
Enclosure type
TEFC
Tab. 9
Compressor motor data
ASD 30
67
ASD 40S
67
ASD 40
69
ASD 30
30
TEFC
ASD 40S
40
TEFC
ASD 40
40
TEFC
ASD 30
3545
3545
1780
ASD 40S
3550
3550
3550
ASD 40
3550
3550
3550
ASD 30
0,75
1080
TEFC
ASD 40S
0,75
1080
TEFC
ASD 40
0,75
1080
TEFC
Fan Motor
Air cooling (option K1)
ASD 25
Rated power [HP]
0,75
]
Rated speed [rpm
1080
Enclosure type
TEFC
Tab. 11
Fan motor data (option K1)
2.8
Cooling oil
Ordering: see Spare Parts, Operating Materials, Service chapter 11.
Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can
form in compressor oils. These deposits block the flow of lubricant and cause excessive
wear and failure of moving parts. Contamination of the lubricant can allow the formation of
acids, causing extensive internal corrosion. Water may be condensed decreasing the lubricity.
Lubricants in rotary compressors does much more than lubricate. During the compression
process, it acts as a sealant in the airend which is important for maximum efficiency. The
lubricant also absorbs much of the heat of compression to cool the airend and reduce the
2 --- 5
Technical Specification
temperature of the compressed air. Its not enough that a compressor cooling oil lubricates
well, it must stand up to the heat, pressure and contaminants that are present in every air
compressor.
2.8.1
General Information
KAESER synthetic lubricants should be stored in a protected location to prevent contamination. Do not re---use drums; flush and send to reconditioner.
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire---resistant fluid. It has a flash point above 460 F. Since the user has total control over the conditions of the compressor lubricant, he assumes total responsibility for its
safe usage.
Material Safety Data Sheets are available for each lubricant from your KAESER authorized
distributors.
Regardless of the lubricant selected, the KAESER Sigma lubricants will separate readily
from water. If condensate occurs it can easily be removed. Let the compressor sit so that
any water can drain back to the separator tank and separate to the bottom. See chapter 10.11 proper draining procedure.
KAESER has several lubricants available that are specially formulated to match these demands. They feature excellent lubricity, outstanding demulsibility (ability to separate from
water), and long life.
M --- SERIES SEMI --- SYNTHETIC LUBRICANTS
M---Series SIGMA compressor cooling oils are the highest quality petroleum lubricants.
M---460 is specially blended to provide reliable performance in KAESER screw compressors.
S--- SERIES SYNTHETIC LUBRICANTS
S---Series SIGMA compressor oils are formulated from the most advanced synthetic
lubricants. These synthetic lubricants begin as high quality petroleum feed stock.
They are then refined, processed and purified into fluids with very consistent molecular
structure. These oils are carefully blended to produce extremely consistant lubricants
with superior properties. SIGMA synthetic lubricants feature all the advantages of both
PAO and diester fluids.
S---460 lubricant is recommended for compressors operating in ambient temperatures
between 40 F and 105 F.
Specialty KAESER LUBRICANTS
S---680 lubricant may be used when ambient temperatures are always between 70 F
and 105 F.
FG---460 synthetic hydrocarbon based food grade lubricant is designed for use in
rotary screw compressors in the application where incidental food contact may occur
with the discharge air. This lubricant meets the requirements of the FDA Regulation 21
CFR 178.3570 and is USDA H ---1 approved and NSF certified. FG---460 is approved
for canning, food packing, meat and poultry processing and other applications where
incidental food contact may occur.
2.8.2
ASD 30
4.2
0.5
ASD 40S
4.2
0.5
ASD 40
4.2
0.5
2 --- 6
Technical Specification
ASD 25
0.3
ASD 30
0.5
ASD 40S
0.5
2.9
ASD 40
0.5
0.5
Electrical Connections
See electrical diagrams in chapter 13.2.4.
2.9.1
Power supply
The machine is designed for an electrical supply according to National Electric Code
(NEC) NEC---670, particulary NFPA 79, section 5.7. In the absence of any user ---specified
alternatives, the limits given in these standards must be adhered to. Consult manufacturer
for any other specific power supply.
Do NOT operate package on any unsymmetrical power supply. Also do NOT operate package on power supplies like, for example, a three---phase (open) delta or three---phase star
with non ---earthed neutral.
Fig. 1
Fig. 2
The machine requires a symmetrical three---phase power supply transformer with a WYE
configuration output as shown in Fig. 1 and Fig. 2.
In a symmetrical three phase supply the phase angles and voltages are all the same.
Other power supplies are not suitable. Please contact KAESERs Application Engineering
department for options.
2.9.2
2 --- 7
Technical Specification
We strongly suggest using a separate copper conductor for the equipment GROUNDING.
NEC Table 250.122 will point out the minimum size, however, we recommend a ground
conductor the same size as the power leads, if local codes allow.
Electrical connections vary in some cases according to the maximum working pressure [psig] of the machine. These are shown in brackets ( ).
Rated power supply 230V 10%, 3 --- ph, 60Hz
ASD 25
Pre---fuse [A]
90 (125)
110
Supply
4xAWG1
(125)
4xAWG1/0
Consumption [A]
66 (125)
75
* Nominal cable temperature 75 C
Tab. 13
Supply 230V/3/60Hz
ASD 30
125
ASD 40S
125
ASD 40
150
4xAWG1*
4xAWG1/0*
4xAWG2/0*
85
98
112
ASD 30
60
4xAWG4
ASD 40S
70
4xAWG3
ASD 40
80
4xAWG2
44
49
56
2.10
7.5 to 9
4.0 ---8.5
< 150
< 1
< 1
< 0.2
70 ---300
< 70
> 1
10 ---500
< 2
2 --- 8
Technical Specification
Dissolved magnesium (Mn) [mg/l]
Dissolved aluminium (Al) [mg/l]
Nitrate (NO3), dissolved [mg/l]
Hydrogen sulphate (SO2) [mg/l]
Free aggressive carbon dioxide (CO2) [mg/l]
Glycol [%]
Solids (particle size) [mm]
Algae
Tab. 15
Water Quality Specification
< 0.1
< 0.2
< 100
< 0.05
< 5
< 50
< 0.1
not allowed
ASD 30
145
ASD 40S
145
ASD 40
145
< 7
1.4401
Cu
210
< 7
1.4401
Cu
210
Flow rate and heat capacity by heating from 110 F to 160 F (equivalent to T= 25 K),
(option W2)
ASD 25
2.42
16.0
ASD 30
2.95
19.5
ASD 40S
3.65
23.9
ASD 40
4.53
27.6
86
99
20550
23732
Flow rate and heat capacity by heating from 60 F to 160 F (equivalent to T= 55 K),
(option W3)
ASD 25
1.10
16.0
ASD 30
1.36
19.5
ASD 40S
1.67
23.9
ASD 40
1.89
27.6
86
99
20550
23732
2 --- 9
Technical Specification
2.11
Refrigeration Dryer
Model
ASD 25
ASD 30
ASD 40S
ASD 40
Model *
* Transfer data from dryer nameplate to the table
Tab. 19
Refrigeration dryer model
Compressed Air System
ABT 37
3
ABT 47
3
ABT 57
3
230
230
ABT 47
R 134a
3.1
305
ABT 57
R 134a
2.4
305
305
305
110
110
100
100
2 --- 10
The machine is made to the latest technical safety standards and acknowledged safety
regulations. Nevertheless, risk of injury and death for the user and third parties and damage to the machine and other property can arise from its use.
The machine may only be used: when it is in technically perfect condition; for the purpose
for which it is intended; and when all safety measures as detailed in the service manual are
put into practice.
In particular, any faults relating to safety must be rectified immediately.
3.1
Correct Use
The machine is intended solely for industrial use in generating compressed air. Any other
use is considered incorrect. The manufacturer is not liable for any damages resulting from
such unspecified use or application. The responsibility, in this case, lies solely with the
user.
Correct use also includes compliance with the data contained in this manual.
The machine may only be used in consideration of the installation conditions.
3.2
Incorrect Use
Untreated compressed air may not be used:
as breathing air,
for any process in which the air can come into contact with food products.
3.3
Users Responsibilities
Personnel
Allow only specialists or persons who have been trained or instructed on this machine to
carry out work on the machine. This applies particularly for:
installation and initial start ---up,
maintenance and service work,
repairs,
inspections.
Allow work to be carried out on electrical equipment only by a qualified electrician or
trained personnel under the supervision of a qualified electrician, and according to electrical engineering regulations.
Ensure that all persons working on the machine have read, understood and observe the
safety ---relevant passages in the service manual.
Give clear instructions on reporting faults and damage to the machine.
Observe the relevant regulations during installation, operation, maintenance and repair of
the machine. These are, for example, valid national laws and safety and accident prevention regulations.
Adhere to inspection schedules and accident prevention regulations
The machine is subject to local inspection schedules.
3 --- 11
3.4
Safety Devices
Do not change, bypass or disable safety devices.
Do not remove or obliterate labels and notices.
Ensure that labels and notices are clearly legible.
More information on safety devices is contained in chapter 4 Design and Function, section 4.4 Safety Devices.
3.5
Hazards
Fundamentals: observe the accepted safety regulations
Observe safety regulations at all times when working on the machine.
Examples of these are requirements and national regulations concerning safety and accident prevention.
3.5.1
Work on the electrical equipment may only be carried out by a qualified electrician or by
instructed persons under the supervision of a qualified electrician.
Before the machine is switched on for the first time the user must provide and check measures to guard against electric shock by direct or indirect contact.
3.5.2
WARNING
3 --- 12
WARNING
Further dangers
Handling cooling and lubricating fluids
Welding
When welding is taking place on or near the machine take adequate measures to ensure
that no parts of the machine or any oil vapors are ignited by sparks.
Spare parts
The use of unsuitable parts may adversely influence the safe operation of the machine.
Use only genuine KAESER spare parts for parts subject to pressure.
3.5.5
Refrigerant
Inhalation:
Remove the affected person to fresh air and keep them calm.
If breathing stops, apply artificial respiration and call for medical assistance.
3 --- 13
3.6
Warning Symbols
Beware of life---threatening electrical voltage.
Do not touch electrical components; danger of electric shock.
Before opening, switch off at the main switch and lock off to secure against
unwanted or accidental switching on.
Warning of hot surface.
Do not touch surface --- danger of burning.
Wear long ---sleeve garments (not synthetics such as polyester) and protective gloves.
Beware --- machine starts automatically.
Machine can start automatically or by remote start command.
Before opening the machine, switch off at the main switch and lock off to
secure against unwanted or accidental switching on.
3.7
Emergencies
3.7.1
Fire supression
Suitable extinguishing media:
foam
powder
carbon dioxide
sand or earth
3.7.2
Cooling oil
Skin contact:
wash off immediately
Eye contact:
rinse thoroughly with lukewarm water and seek medical assistance.
If necessary, request a copy of the safety data sheet for KAESER lubricants.
3.7.3
Refrigerant
Inhalation:
Remove the affected person to fresh air and keep them calm.
If breathing stops, apply artificial respiration and call for medical assistance.
3 --- 14
3.8
Environmental Protection
Do not allow cooling oil to escape to the environment or into the sewage system.
Store and dispose of used materials and replaced parts in accordance with local environment protection regulations. Observe national regulations. This applies particularly to parts
contaminated with cooling oil.
Do not allow refrigerant to escape into the atmosphere.
3 --- 15
4.1
Machine Overview
4.1.1
Cabinet
Fig. 3
Cabinet
Function
Items in brackets [ ] correspond to the Pipe and Instrument Flow Diagram (P & I Diagram)
in chapter 13.2.1.
An air ---cooled machine serves to illustrate function.
4 --- 16
Fig. 4
1
2
3
4
5
6
7
8
9
Control cabinet
Oil separator tank [6]
Air filter [1]
Oil/air cooler [11/13]
Add ---on cabinet for frequency converter /
refrigeration dryer
Compressor
Atmospheric 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. The cooling effect directly
within the compression chamber ensures a low airend discharge temperature.
Cooling oil is recovered from the compressed air in the oil separator tank (7) and is then
cooled in the oil cooler (9). The oil then flows through the filter (4) and back to the point of
injection. Air pressure within the machine keeps the oil circulating and therefore a separate
pump is not necessary. A thermostatic valve maintains optimum oil temperature.
Compressed air, freed of its oil content in the separator tank (7), flows through the minimum pressure/check valve (8) into the aftercooler (9). The minimum pressure/check valve
ensures there is always sufficient air pressure to maintain cooling oil circulation.
The aftercooler brings down the compressed air temperature to 5 to 10 K above ambient.
Most of the moisture carried in the air is removed in the aftercooler.
4 --- 17
Fig. 5
10
11
12
4 --- 18
Options
4.2.1
Fig. 6
4.2.2
Machine mountings
Fig. 7
1
4.2.3
Heat recovery
External heat recovery (option W1)
Connections are provided and bridged.
An external heat recovery system can be retro ---fitted at any time.
Internal heat recovery (option W2 / W3)
A plate heat exchanger (1) is installed for heat recovery.
Fig. 8
1
4.2.4
4 --- 19
4.3
4.3.1
Operating states
There are three operating states:
LOAD: the inlet valve is open. The airend delivers compressed air to the system.
The drive motor runs under full load.
IDLING: 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 drive 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.
PARTIAL LOAD (option C1): The proportional controller continuously varies the degree
of opening of the inlet valve, and thereby the delivery rate of the compressor, in response and in proportion to the air demand. The airend delivers compressed air to the
system.
The load and power consumption of the drive motor rises and falls with the air demand.
4.3.2
Controller Operation
Using the selected control mode, the controller switches the compressor between its various operational states in order to maintain system pressure between the set minimum and
maximum values.
According to the individual compressed air demand one of the various control modes available will provide the optimum duty cycle for the machine.
4.3.3
Control Modes
The following control modes are available:
DUAL
VARIO
QUADRO
DUAL
In the DUAL control mode, the compressor is switched back and forth between full load
and idle to maintain system pressure between the set minimum and maximum values.
When the maximum pressure is reached the machine switches to IDLING. When the preset
idling time has elapsed the machine is switched to STANDSTILL.
The shorter the idling time setting, the sooner and more frequently the motor is stopped.
VARIO
The VARIO control mode is an extension of DUAL control. The difference being that under
VARIO control the idling time is automatically adjusted corresponding to the increased or
decreased maximum switching frequency of the drive motor.
4 --- 20
4.3.5
4.4
Control mode
Advantage
Disadvantage
CONTINUOUS
TIMER
Safety Devices
The following safety devices are provided and may not be changed:
EMERGENCY STOP button
The EMERGENCY STOP button shuts down the compressor immediately. The motor
remains still. The pressure system is vented.
Safety relief valve
The safety relief valve protects the system from excessive pressure. This is factory set.
Housing and covers for moving parts and electrical connections.
Protection from accidental contact.
4 --- 21
Fig. 9
Symbol
Item Description
1
Function
ON (I)
OFF (0)
Operating mode:
Clock
Operating mode:
Remote control
Operating mode:
LOAD / IDLE
Arrow key
Arrow key
Escape
Return/enter/save
key
4 --- 22
Item Description
10
11
Function
Displays the event memory.
Selection from every menu.
Returns together with esc key (8).
Acknowledges (re---sets) messages and resets the
event memory (if permitted).
Tab. 22
Fig. 10
Symbol
Item Description
Function
12
Display
13
Alarm
14
Communication
15
Service/warning
LED
16
Controller power
ON
17
LOAD
18
Operating mode
IDLE
19
Tab. 23
Machine ON
4 --- 23
5.1
Ambient Conditions
There must be no open flames or sparks at the place of installation.
Any welding work carried out on the equipment must not cause a fire hazard through
flying sparks or excessive temperature.
The machine is not explosion ---proof.
Do not operate in areas in which specific requirements with regard to explosion
protection are applied.
Clean inlet air with no damaging contaminants.
Inlet air free of explosive or chemically unstable gas or vapor.
Ambient temperature must be acceptable and stable.
The airend discharge temperature must remain constant to prevent the build ---up of
condensate.
Suitable fire extinguishing material must be readily available.
5.2
Installation Conditions
5.2.1
Fig. 11
A
B
Z
Exhaust fan
Exhaust air duct
Inlet air opening
5 --- 24
Ventilation
Values given are minimum guidelines.
If the inlet aperture is insufficient a dangerous vacuum can be created in
the compressor room.
Ensure that the volume of air flowing into the compressor room is at
least equivalent to that being removed from it by the compressor and
exhaust fan.
Make sure that the machine and exhaust fan can only operate when
the inlet aperture is actually open.
ASD 25
6.5
5297
ASD 30
7.5
5886
ASD 40S
8.6
7063
ASD 40
8.6
8240
25 1/2x25 1/2
25 1/2x25 1/2
25 1/2x25 1/2
Exhaust ducting
Consult the manufacturer on the design of the ducting, length, number of bends, etc.
Further information on exhaust air ducts can be found in chapter 13.2.3.
5.2.3
5 --- 25
Installation
6
Installation
6.1
Safety
Severe injury or death can result from compressed air.
DANGER
WARNING
Installation may only be carried out by persons fully trained in the basic safety concepts of
compressed air engineering.
6.2
6.3
Fig. 12
1
2
6 --- 26
Installation
Shut ---off valve (2) to be installed by the user in the connection line.
Make the compressed air connection with a flexible hose (1) or an axial compensator (1).
6.4
Electrical Connection
Main power supply and overcurrent protection must be installed by a qualified electrician in
accordance with NEC, OSHA, and any applicable local codes.
Use wire conductor dimensions and fuse ratings in accordance with local regulations.
Guide values are given in chapter 2.9.
The user must provide the machine with a lockable supply ---disconnecting device.
This could be, for example, a switch ---disconnector with fuses. If a circuit breaker is
used it must be suitable for the motor starting characteristics.
Before initial start--- up
The control transformer in the control cabinet has connections for various supply voltages. Check that the correct connections are made for the supply voltage provided for
the machine. If necessary, re---connect the transformer using the 5% taps to match
the supply voltage.
Connect the machine to the mains power supply in accordance with the electrical diagram in chapter 13.2.4.
6.4.1
Fig. 13
Open the terminal box and change the jumpers as shown in the electrical diagram.
6 --- 27
Installation
Changing the jumpers in the fan motor terminal box.
Example:
Fig. 14
Open the terminal box and change the jumpers as shown in the electrical diagram.
Connecting the overload protection relay
Overload protection cut ---outs for both main voltages are already provided in the control
cabinet.
Presetting:
Some values are dependent on the machine working pressure [psig], which is shown in
brackets ( ).
ASD 25
ASD 30
38 (125)
50
44
460V, 3 ---ph, 60Hz [A]
19 (125)
25
22
Tab. 25
Overload protection relay settings.
230V, 3 ---ph, 60Hz [A]
ASD 40S
57
ASD 40
66
29
33
Example:
Fig. 15
1
2
6 --- 28
Installation
Mount the reserve overload protection relay (1) on the motor starter ( ---K1M) and connect up.
Check the overload protection relay pre---settings.
Connecting the motor protection switch
Motor protection switches for both main voltages are already provided in the control cabinet.
Presetting:
ASD 25
230V, 3 ---ph, 60Hz [A]
3.3
460V, 3 ---ph, 60Hz [A]
1.7
Tab. 26
Motor protection switch settings.
ASD 30
3.3
1.7
ASD 40S
3.3
1.7
ASD 40
3.3
1.7
Example:
Fig. 16
1
2
6 --- 29
Installation
Connect the control transformer.
Example:
Fig. 17
1
Control transformer
Open the control cabinet and connect the control transformer in accordance with the
electrical diagram.
Connecting the dryer control transformer (option T2) for models equipped with a refrigeration dryer only
Power for the refrigeration dryer (if one is present) is provided by the control transformer.
This is not required for 460V main.
Example:
Fig. 18
1
Transformer connection
Transformer terminals
Open the control cabinet and insert the jumpers in the terminal strip ---X31 in accordance with the electrical diagram.
6 --- 30
Installation
6.5
< 200
Fig. 19
1
2
Drain hose
Condensate collecting line
6.6
Options
6.6.1
6.6.2
6.6.2.1
6 --- 31
Installation
Fig. 20
A
B
Heat recovery
Outlet
Inlet
10
12
17
6.6.2.2
Slowly open the inlet (B) shut ---off tap to gradually fill the heat exchanger with water.
6 --- 32
Initial Start--- up
7
Initial Start---up
7.1
36 months
7.2
Action
Change the oil filter.
Change the oil separator cartridge.
Change the cooling oil.
Have the motor bearings checked by an authorized
KAESER service agent.
Have the overall technical condition checked by an authorized KAESER service agent.
7.3
Chapter
5
6.4
2
2.9.2
Done?
6.3
6.3
7.5
7.4
6.6.1
4.1.1
7 --- 33
Initial Start--- up
Setting
The standard setting is made at the factory.
To prevent the overload protection cutout from being triggered by voltage fluctuations, temperature influences or component tolerances, the setting can be up to 15% higher than the
arithmetical phase current.
7.4
7.5
A sticker giving the type of oil used is found near the oil separator tank filling port.
Fig. 21
1
2
Screw plug
Inlet valve
Remove the plug (1) from the inlet valve (2).
Pour cooling oil into the airend.
7 --- 34
Initial Start--- up
Fig. 22
1
2
Coupling
Compressor block
Coupling
Remove the cover (3).
3
4
Cover
Rotational direction arrow
7.6
7.7
Initial Start---up
Open the shut ---off valve to the air network.
Switch on at the main supply isolator.
The controller makes a self---test and the green LED Power ON lights.
Press the Operating state LOAD/IDLE key.
Press the ON key.
The green LED Machine ON lights.
Allow the machine to idle for at least one minute.
This ensures good distribution of cooling oil.
Press the Operating state LOAD/IDLE key.
The machine switches to the LOAD state and delivers compressed air.
Watch for any faults occurring in the first hour of operation.
After the first 50 operating hours carry out the following:
Check that all electrical connections are tight.
7 --- 35
Initial Start--- up
7.8
7 --- 36
Operation
8
Operation
Fig. 23
1
2
3
4
8.1
5
6
7
8
13
Remote key
LOAD LED
IDLELED
Power ON LED (green)
LOAD / IDLE toggle key
8.1.1
Switching on
Compressed air can cause serious injury!
WARNING
Automatic restart
Pre --- condition: System pressure is lower than cut ---out pressure.
Automatic restart is factory ---set.
The machine restarts automatically when power is resumed after a power cut.
8 --- 37
Operation
8.1.3
Switching Off
Press the LOAD/IDLE toggle key (13).
The machine switches to IDLE and the LED (7) blinks.
After running in idle for 20 seconds, press the OFF key (3).
The Machine ON LED goes out (1).
Switch off and lock out the main supply isolator.
8.2
Fig. 24
9
Switching off
Press the EMERGENCY STOP button (9)
The EMERGENCY STOP remains latched in.
The machine pressure system is vented and the machine is prevented from re---starting.
Starting again
Pre --- condition: Fault rectified.
Turn the EMERGENCY STOP button in the direction of the arrow to unlatch it.
Press the Reset key (11).
Switch the machine on.
8.3
8 --- 38
Operation
Apply the remote warning label to the machine where it is plainly visible.
BEWARE! This machine is remotely controlled and can start at any
time.
Label the remote control device accordingly:
Before starting, make sure that no one is working on the machine and
it can be safely started.
8.4
8.5
Fig. 25
10
11
12
Alarm
An alarm shuts the machine down automatically. The red Alarm LED blinks (11).
Warning
The display shows a maintenance or warning message.
The yellow warning LED (10) blinks, for example, if a maintenance task is due.
8.5.1
8 --- 39
Operation
Press the Acknowledgement (reset) key (12).
The alarm LED (red) goes out (11).
The machine is now ready to start again.
8.5.2
8 --- 40
9.1
Indicated by
Blinking red LED
see chapter
9.1
9.2
No indication
9.3
Possible cause
Action
access doors
ADT
ADT dT/dt
airend rotation
AI 1 open cct.
AI 2 open cct.
Short circuit to
earth.
Connection is broken between the internal pressure
transducer and analog input 2.
KAESER service
technician only
Ensure adequate
ventilation.
Ensure permitted
room temperature
not exceeded.
Clean the cooler.
Cooling air outlet too
near a wall
Check the cooling
oil level.
Check airend and
piping to airend.
Check the cooling
oil level.
Check oil circulation.
Changeover phase
lines L1 and L2.
Check line and connection.
Short circuit to
earth.
9 --- 41
Possible cause
Action
AI 3 open cct.
AI 4 open cct.
KAESER service
technician only
Check the sensor.
Replace defective
sensor.
blowoff prot.
condensate drain
Fault in condensate
drainage.
Cooling water pressure too low.
Check condensate
drainage.
Check cooling water
supply.
Check that cooling
water shut ---off valve
is fully open.
AI 5 open cct.
AI 6 open cct.
Short circuit to
earth.
There is no connection between the
sensor allocated to
an analog input and
the input itself.
Short circuit to
earth.
...
AI 8 open cct.
AI 1 short cct.
...
AI 8 short cct.
back pressure
coolingwater low
Check
minimum
pressure/check
valve.
Check the minimum
pressure/check
valve, the control
valve and the inlet
valve.
Check sensor, line
and connection.
9 --- 42
Possible cause
Action
EMERGENCYSTOP
EMERGENCY STOP
button pressed.
Investigate cause.
ext. message 0
...
ext. message 5
Fan M2 I
Fan M3 I
Fan M4 I
HT cell
mains cont. off?
mains monitor
model
KAESER service
technician only
motor I
motor T
motor bearings
neutral p ---switch
neutral T---switch
9 --- 43
Possible cause
Action
no press. buildup
Machine produces
no compressed air.
O 0.6/A 0.7
O 1.6/A 1.7
oil p
PD temperature
PD temperature
Power supply
pRV
RD compr. p
Compressor outlet
temperature too low.
Compressor outlet
temperature too
high.
2. Power failure
KAESER service
technician only
Check the inlet
valve.
Check minimum
pressure/check
valve.
Ensure adequate
ventilation.
Replace defective
sensor.
9 --- 44
Possible cause
Action
RD compr. T
KAESER service
technician only
Ensure adequate
ventilation.
Install an extractor.
Cleaning the cooler
RD compr. T
separator dp
separator T
SIGMA CONTROL T
softstart
start T
Check refrigeration
dryer.
Replace the oil separator cartridge.
Check the cutout
line.
Ensure adequate
ventilation.
Ensure permitted
room temperature
not exceeded.
Check control cabinet ventilator (filter
mats).
Replace the
V---belts.
Check the frequency
converter.
9 --- 45
Possible cause
Action
access doors
ADT
air filter dp
air filter h
Bearing
maintenance h
blowoff prot.
Buffer battery
bus alarm
condensatedrain
elect. equip. h
ext.load signal?
KAESER service
technician only
Ensure adequate
ventilation.
Clean the cooler.
Cooling air outlet too
near a wall.
Check the cooling
oil level.
Replace the oil filter.
Clean/replace the air
filter element.
Check condensate
drain and lines.
Reset the service interval counter.
Check settings of
the external controller.
Take the pressure
drops across filters
and dryer into account.
Check electrical
components.
9 --- 46
Possible cause
Action
error: RS 485
Wrong configuration
or transmission error.
ext. message 0
...
ext. message 5
flash memory
Internal controller
memory error.
1. power failure:
Machine was re--started automatically.
mains voltage
modem problem
SIGMA CONTROL
does not recognize
the modem.
motor T
motor bearings h
motorstarts /h
motor starts /d
neutral p ---switch
The permissible
number of motor
starts was exceeded
in the last 24 hours.
KAESER service
technician only
Check maximum
cable length and
screening.
Check interface parameters.
1 master and 1 slave
configured.
Rectify fault.
Check pressure
transducer.
Replace defective
sensor.
Check pressure
transducer.
Replace defective
sensor.
9 --- 47
oil change h
oil filter dp
oil filter h
oillevel
oil T
Possible cause
The compressor
cannot build ---up
pressure.
Action
Rectify fault
Check for air leaks.
Check the value given in the analog
data menu with the
reading on the oil
separator tank pressure gauge.
Change the cooling
oil.
Warning
Compressor outlet
temperature is low.
Clean the cooler.
Check the cooling
oil level.
Warning
The purest class oil
content limit will
soon be reached.
Remaining oil
content
separator dp
RAM
Replace defective
switch.
Install auxiliary heating.
Warning
Compressor discharge temperature too high.
Internal RAM defective.
PD temperature
KAESER service
technician only
Check controller.
Exchange the controller.
Check the oil separator cartridge.
Check oil sensor line
and connection.
9 --- 48
Possible cause
Action
separator h
set output
System pressure
System pressure
has fallen below the
set high value.
VFD mains
Failure of power
supply to the frequency converter.
V---belt tension too
low.
The service interval
to the next V---belt
re---tensioning has
expired.
V---belt tension
V---belt tens. h
Tab. 29
9.3
KAESER service
technician only
Check pressure
transducer.
Replace defective
sensor.
Re---tension the
V---belts.
Re---tension the
V---belts.
Possible cause
Action
Check setting.
KAESER service
technician only
Replace the overload relay.
Check pressure
drop across the separator cartridge.
Change the oil separator cartridge if necessary.
Open the shut ---off
valve in the venting
line.
9 --- 49
Possible cause
Hose coupling or
maintenance hose
still plugged into the
quick ---release
coupling on the oil
separator tank.
Oil level in the separator tank too high.
Hose coupling or
maintenance hose
still plugged into the
quick ---release
coupling on the oil
separator tank.
Oil cooler leaking
Connection leaking.
Tab. 30
Action
KAESER service
technician only
Check the valve.
Install auxiliary
compressor.
Remove coupling or
maintenance hose.
9 --- 50
Maintenance
10
Maintenance
10.1
Safety
Disregarding these notes and/or improper handling may result in serious injury.
Electric shock can kill!
DANGER
WARNING
WARNING
CAUTION
10 --- 51
Maintenance
Maintenance work may only be carried out:
by persons trained in the machine and persons under the supervision of an expert,
by experts,
by an authorized KAESER service agent.
Work on electrical devices may only be carried out in accordance with electrical regulations:
by persons trained in the machine under the supervision of an
electrician,
by an electrician,
by an authorized KAESER service agent.
10.2
Maintenance Schedule
Maintenance intervals are recommendations only and should be adjusted
to suit the installation and operating conditions.
According to the way a machine is equipped, sensors and/or maintenance interval counters monitor the operational state of important functional devices. Necessary maintenance
tasks are signalled by the SIGMA controller.
This enables the frequency of individual maintenance tasks to be compared with KAESERs recommendations. A list is given in chapter 10.16.
10.2.1
10 --- 52
Maintenance
10.2.2
Indicated by
SIGMA CONTROL
Indicated by
SIGMA CONTROL
but at least annually.
Indicated by
SIGMA CONTROL
but at least every
3 years.
Every 3000 h
variable (see
chapter
LEERER MERKER)
Annually
Maintenance tasks
Check cooling oil level.
Clean or renew the filter mats.
Oil and air cooler maintenance.
Heat recovery system maintenance.
Clean the refrigerant condenser.
Air filter maintenance.
see chapter
10.10.1
10.3.2 / 10.6
10.3
10.4
10.15.1
10.5
10.12
10.14
10.8
10.11
10.13
10.3
10.15.3
h = operating hours
Tab. 31
Regular maintenance work
10 --- 53
Maintenance
10.2.3
DESCRIPTION
LUBRICANT
MAXIMUM RECOMMENDED
CHANGE INTERVAL*
First Oil Change
Subsequent Oil
Change
M---460
2000 Hours
3000 Hours
S---460
6000 Hours
8000 Hours
SIGMA
DESCRIPTION
LUBRICANT
MAXIMUM RECOMMENDED
CHANGE INTERVAL*
First Oil Change
Subsequent Oil
Change
S---680
6000 Hours
8000 Hours
FG---460
2000 Hours
3000 Hours
10 --- 54
Maintenance
10.3
Cooler Maintenance
10.3.1
brush
vacuum cleaner
Fig. 26
1
2
10.3.2
Cooler
Brush
Dry brush the cooler (1) and use a vacuum cleaner to suck up the dirt.
10 --- 55
Maintenance
Fig. 27
1
2
3
Filter mat
Retaining frame
Fixing
Removal
Unlock the fixings (3).
Use a screwdriver to turn the fixing 90 anti---clockwise.
Remove the frame (2).
Cleaning
Beat the mat (1) or use a vacuum cleaner to remove loose dirt. If necessary, wash the
mat in lukewarm water and household detergent then rinse thoroughly.
Replace the mat if cleaning is not possible or has already been carried out five times.
Replacing
Replace the frame and close the fixings.
Press and turn the fixings 90 clockwise until they latch.
10.4
10 --- 56
Maintenance
10.5
Fig. 28
1
2
3
Nut
Nut
Rear side
4
5
10 --- 57
Maintenance
Close the air filter housing
Clean all parts and sealing surfaces.
Insert the air filter element (4) in the cover (5) and place on the rear side (3).
Secure the air filter housing with the screw and wing nut (2).
Insert the air filter housing in the side panel and secure the cover (5) with the wing
nut (1).
Close all access doors and replace all cover panels.
Switch on the power supply and reset the maintenance interval counter.
10.6
Fig. 29
1
2
Ventilator grill
Ventilator grill
Filter mat
Removal
Remove the ventilator grill (1) and the filter mat (2).
Cleaning
Beat the mat or use a vacuum cleaner to remove loose dirt. If necessary, wash the mat
in lukewarm water (40 C) and household detergent then rinse thoroughly.
Renew the mat if cleaning is not possible or has already been carried out five times.
Replacing
Lay the filter mat in the frame and push on the grill to latch.
10 --- 58
Maintenance
10.7
10.8
Severe injury could result from touching the coupling while it is rotating.
Never switch the machine on without the guard in place over the coupling.
noisy operation,
surface cracks,
color change.
Fig. 30
1
2
Safety screen
Coupling
10 --- 59
Maintenance
10.9
Compressed air and devices under pressure can injure or cause death if
the contained energy of the air is released suddenly or uncontrolled.
After shutting down the compressor and venting the oil separator tank
there is still pressure on the check valve from the air main.
Close the shut ---off valve provided by the user to isolate the machine
from the air main.
Vent the oil separator tank.
Vent the air aftercooler to completely depressurize the system between
the users shut ---off valve and the minimum pressure/check valve.
Escaping oil mist is damaging to health.
CAUTION
Before undertaking any maintenance or service work on the pressure system the machine
must be isolated from the air system and completely vented.
The machine is vented in three stages:
the oil circuit vents automatically when the machine is switched off,
air is vented manually from the oil separator tank,
air is vented manually from the air cooler.
Venting
Close the users shut ---off valve between the machine and the air main.
If no shut ---off valve is provided, the complete air system must be vented.
The hose coupling, shut ---off valve and maintenance hose lie beneath the
oil separator tank.
10 --- 60
Maintenance
Fig. 31
1
2
6
7
After automatic venting the pressure gauge does not read zero?
Make sure that the shut ---off valve is closed.
If manual venting does not bring the oil separator tank pressure gauge
to zero, call KAESER service.
Manually venting the oil separator tank
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupling (3).
Open the shut ---off valve (7) slowly to release pressure.
Withdraw the male hose fitting and close the shut ---off valve.
Manually venting the compressed air cooler
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupling (1).
Open the shut ---off valve (7) slowly to release pressure.
Withdraw the male hose fitting and close the shut ---off valve.
10.10
10 --- 61
Maintenance
Fig. 32
2
3
4
5
min
OK
max
Cooling oil
CAUTION
Venting
Close the users shut ---off valve between the machine and the air main.
If no shut ---off valve is provided, the complete air system must be vented.
The hose coupling, shut ---off valve and maintenance hose lie beneath the
oil separator tank.
10 --- 62
Maintenance
Fig. 33
1
2
3
5
6
7
10 --- 63
Maintenance
10.11
Cooling oil
Have the oil container ready.
Thoroughly drain the oil from the separator tank, the cooler and the heat recovery system if
fitted.
Dispose of the used oil in accordance with local environment protection regulations.
Danger of burning from hot components and oil.
CAUTION
Fig. 34
1
2
6
7
9
10
11
4
5
10 --- 64
Maintenance
Close the shut ---off valve (10) in the venting line.
Start the machine in idle and watch the oil separator tank pressure gauge (2) until it
reads 40 ---70 psig.
Switch the machine off.
Switch off and lock out the main supply isolator.
Wait at least two minutes for oil to flow back to the separator tank.
Alternative: Oil changing with help from an external pressure source
Pre --- condition: Machine switched off.
Mains isolator locked off
Machine fully vented (no pressure).
Pressure gauge on the oil separator tank indicates zero.
External source of compressed air available.
Close the shut ---off valve (10) in the venting line.
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupling (3).
Connect the maintenance hose to an external air supply.
Open the shut ---off valve (7) until the pressure gauge on the oil separator tank reads
40 ---70 psig.
Close the shut ---off valve (7) and withdraw the hose fitting from the coupling.
Draining the oil from the separator tank
Contact KAESER service if condensate is detected in the oil.
It is necessary to adjust the airend discharge temperature to suit operating
conditions.
Have the oil container ready.
With the shut ---off valve closed, insert the male hose fitting (6) into the hose coupling (9).
Place the end of the maintenance hose in the oil container and secure it in place.
Open the shut ---off valve (11).
Open the shut off valve (7) in the maintenance hose slowly and close when air escapes.
Close the shut ---off valve (11) and unplug the hose.
10 --- 65
Maintenance
Draining the oil from the cooler
Fig. 35
1
2
3
Oil cooler
Hose coupling (oil drain)
Shut ---off valve
6
7
10 --- 66
Maintenance
10.12
Spare parts
Have the oil container ready.
Fig. 36
1
2
Oil filter
Direction to unscrew
Dispose of parts and materials contaminated with oil in accordance
with local environment protection regulations.
Unscrew the oil filter counter ---clockwise, catch oil spillage and dispose of correctly.
Lightly oil the new oil filter gasket.
Screw on the new filter using hand pressure only. Do not use any tool.
10 --- 67
Maintenance
10.13
10.14
Spare parts
Precision pressure gauge
Cleaning rags
10 --- 68
Maintenance
Fig. 37
14
15
16
17
Cover
Dirt trap
Air pipe
Retaining bolt
19
Pipe fitting
20
Fitting
21
Gasket
23
Oil separator cartridge
25
Minimum pressure/check valve
Unscrew the fitting (20) and carefully put the parts to one side; pull out the copper
pipe at item (15).
Unscrew the fittings (19) from the ends of the air pipe (16).
Withdraw the air pipe from the minimum pressure/check valve (25) and push carefully
to one side.
Remove the cover retaining bolts (17) and carefully lift the cover (14).
The oil separator element cannot be cleaned.
10 --- 69
Maintenance
10.15
Refrigeration Dryer
Compressed air
vacuum cleaner
Fig. 38
6
7
8
Refrigerant condenser
Screws
Cover
Refrigerant condenser
Remove the screws (6) and take off the cover (7).
Use compressed air (< 70 psig) to blow the condenser (8) through from outside to
inside and then vacuum up the dirt.
Replace the cover.
10 --- 70
Maintenance
Fig. 39
1
TEST button
Press and hold the TEST button (1) for at least two seconds.
Compressed air
Cleaning rags
Spare parts (as required)
10 --- 71
Maintenance
Fig. 40
1
2
3
4
5
6
Screw
Diaphragm
Screw
Diaphragm seat
Compression spring (diaphragm)
Diaphragm cover
7
8
9
10
11
Fitting
Compression spring (valve core)
Valve core
Housing
Cap
10 --- 72
Maintenance
10.16
Tab. 35
Operating hours
Signature
Maintenance log
10 --- 73
11.1
11.2
11.3
Quantity
1
2
1
1
1
1
material number
1250
1100
1050
1200
1450
1600
Maintenance Contract
Sign a maintenance contract with an authorized KAESER service agent.
This ensures the utmost reliability and availability of your compressed air supply system.
11.4
Service Addresses
Address of KAESER agents are given at the end of this manual.
11.5
11 --- 74
12.1
De ---commissioning
De---commissioning is necessary when:
the machine will not be needed for some time,
the machine is to be moved to another location,
the machine is no longer needed,
the machine is to be scrapped.
Temporarily out of service
Pre --- condition: The machine can be started at regular intervals.
Run the machine once a week under load for at least 30 minutes to ensure corrosion
protection.
12.2
In water ---cooled machines, disconnect the water supply and drain all water from the
machine.
Packing
Equipment:
Desiccant
Plastic sheeting
Wooden transport crate
Transport packing
A wooden crate is required for ground transportation to protect the machine from mechanical damage.
Consult an authorized KAESER service agent for advice on packing for sea or air transport.
12.3
Storage
Pre --- condition: The machine is adequately packed.
12 --- 81
Transporting
Use only a fork truck or lifting cradle.
Take weight and centre of gravity into consideration. The centre of gravity is shown in the
drawing in chapter 13.2.3.
The water cooling system of water ---cooled machines must be drained
completely if there is danger of frost.
Fork truck
Pre --- condition: The whole machine is over the forks.
Fig. 41
Lifting cradle
Pre --- condition: No pressure on the sides of the machine cabinet.
Fig. 42
1
12.5
Spreader bar
Disposal
Pre --- condition: Machine is de---commissioned.
The sealed refrigerant circuit still contains both refrigerant and oil.
Both must be drained and disposed of by an authorised body.
12 --- 82
12 --- 83
Annex
13
Annex
13.1
Conformity
Machines with CE mark conform to European directives and may be operated in the EU.
A Declaration of Conformity is provided with the machine.
13.2
13.2.1
13 --- 84
Appendix
13.2.2
13 --- 90
Appendix
13.2.3
Dimensional drawing
13 --- 96
Appendix
13.2.4
Electrical diagram
13 --- 99