KAESER ASD T Series

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13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ........... 98

13.3 Dimensional Drawing ....................................................................................................... 104

13.4 Electrical Diagram ............................................................................................................ 107

Contents

Service Manual Screw Compressor

ASD T Tri-Voltage 9_5721 06 USE

Main Page

Table of Contents3
Regarding this Document Using the Document11
Additional Documents11
Copyright11
Symbols and Identification11
Warnings11
Other Instructions and Symbols12
Tab. 1 the Levels of Danger and Their Meaning12
Technical Data Nameplate13
Options13
Tab. 2 Nameplate13
Weight14
Temperature14
Ambient Conditions14
Tab. 3 Options14
Tab. 4 Machine Weight14
Tab. 5 Temperature14
Tab. 6 Ambient Conditions14
Ventilation15
Pressure15
Fig. 1 Maximum Relative Humidity15
Tab. 7 Ventilation15
Tab. 8 Safety Relief Valve Setting15
Delivery16
Cooling Oil Recommendation16
Basic Information16
KAESER Lubricants16
Tab. 9 Delivery16
Cooling Oil Volume17
Tab. 10 Cooling Oil Charge17
Tab. 11 Cooling Oil Charge (Option W1)17
Tab. 12 Cooling Oil Charge (Option W2)17
Motors and Power18
Drive Motor18
Fan Motor18
Sound Pressure Level18
Tab. 13 Cooling Oil Charge (Option W3)18
Tab. 15 Drive Motor Rated Speed18
Tab. 16 Fan Motor18
Power Supply19
Power Supply Specifications19
Fig. 2 Three-Phase Star (Wye); 4 Wire; Grounded Neutral19
Fig. 3 Three-Phase Star (Wye); 3 Wire; Grounded Neutral19
Tab. 17 Sound Pressure Level19
Heat Recovery20
Prepared for External Heat Recovery20
Tab. 18 Supply 208V/3/60Hz20
Tab. 19 Supply 230V/3/60Hz20
Tab. 20 Supply 460V/3/60Hz20
Tab. 21 Heat Capacity (Option W1)20
Internal Heat Recovery21
Tab. 22 Water Quality Specification21
Tab. 23 Heat Exchanger Specification (Option W2/W3)21
Refrigeration Dryer22
Tab. 24 Heat Capacity (Option W2/W3)22
Tab. 25 Flow Rate (Option W2)22
Tab. 26 Flow Rate (Option W3)22
Tab. 27 Refrigeration Dryer: Model22
Tab. 28 Refrigeration Dryer: Compressed Air System23
Tab. 29 Refrigeration Dryer: Refrigeration Circuit23
Safety and Responsibility Basic Information24
Specified Use24
Improper Use24
User's Responsibilities24
Observe Statutory and Universally Accepted Regulations24
Qualified Personnel25
Adhere to Inspection Schedules and Accident Prevention Regulations25
Dangers25
Safely Dealing with Sources of Danger26
Safe Machine Operation28
Organizational Measures28
Danger Areas28
Safety Devices29
Safety Signs29
Tab. 30 Danger Areas29
Fig. 4 Location of Safety Signs30
In Emergency31
Fire Fighting31
Tab. 31 Safety Signs31
Remove any Compressor Cooling Oil from Your Person32
Injury from Handling Refrigerant32
Warranty32
Environmental Protection33
Design and Function34
Enclosure34
Functional Description of the Machine34
Fig. 5 Enclosure34
Fig. 6 Machine Layout35
Refrigeration Dryer36
Floating Relay Contacts36
Options36
Machine Mountings36
Fig. 7 Refrigeration Dryer36
Fig. 8 Machine Mountings36
Cooling Air Filter Mat37
Heat Recovery37
Optional Filter Monitoring Set37
Fig. 9 Cooling Air Filter Mat (Option K3)37
Fig. 10 Internal Heat Recovery (Option W2/W3)37
Operating States and Control Modes38
Operating States of the Machine38
Control Modes38
Refrigeration Dryer Control Modes39
Tab. 32 Operating States under MODULATING Control39
Tab. 33 Refrigeration Dryer Control Modes39
Safety Devices40
SIGMA CONTROL Keys and Indicators40
Fig. 11 Keys40
Fig. 12 Indicators41
Tab. 34 Keys41
Tab. 35 Indicators41
Installation and Operating Conditions42
Safety42
Installation Conditions42
Place of Installation and Distances42
Ensure Adequate Ventilation43
Exhaust Duct Design43
Fig. 13 Recommended Installation and Dimensions [Inch]43
Using the Compressor to Supply a Compressed Air System44
Installation Safety45
Reporting Transport Damage45
Making the Compressed Air Connection45
Connecting the Condensate Drain46
Fig. 14 Compressed Air Connection46
Fig. 15 Condensate Drain Dimensions [Inch]46
Making the Power Supply Connection47
Changing Main Voltage Connections47
Tab. 36 Voltage Selection47
Tab. 14 Drive Motor48
Tab. 37 Overload Protection Relay Settings48
Tab. 38 Motor Protection Switch Settings48
Refrigeration Dryer: Connecting the Transformer According to the Power Supply49
Options49
Anchoring the Machine49
Initial Start-Up Safety50
To be Noted before Commissioning50
Checking Installation and Operating Conditions51
Tab. 39 Re-Commissioning after Storage51
Tab. 40 Installation Conditions Checklist51
Setting the Overload Protection Cut-Out52
Setting the Motor Overload Protection Switch52
Pouring Cooling Oil into the Airend52
Fig. 16 Inlet Valve Filling Port52
Check Direction of Rotation53
Starting the Machine for the First Time53
Fig. 17 Coupling53
Setting the Setpoint Pressure54
Changing the Display Language54
Fig. 18 Label: Changing the Display Language55
Operation56
Switching on and off56
Switching on56
Shutdown56
Fig. 19 Switching on and off56
Switching off in an Emergency and Switching on Again57
Remote on and off Switching57
Fig. 20 Switching off in an Emergency57
Switching on and off with the Clock58
Fig. 21 Switching on and off in Remote58
Tab. 41 Machine Identification58
Tab. 42 Remote Control Identification58
Acknowledging Alarm and Warning Messages59
Fig. 22 Switching on and off with the Clock59
Tab. 43 Machine Identification59
Fig. 23 Acknowledging/Resetting Messages60
Fault Recognition and Rectification61
Basic Information61
Alarm Messages (Machine Shut-Down)61
Tab. 44 Alarm Messages and Measures61
Warning Messages (Yellow LED Lights)64
Other Faults68
Tab. 45 Warning Messages68
Tab. 46 Other Faults and Actions69
10.1 Maintenance70
Safety70
Maintenance Schedule70
Logging Maintenance Work70
Resetting Maintenance Interval Counters71
Regular Maintenance Tasks71
Tab. 47 Regular Maintenance Tasks71
Cooling Oil Changing Interval72
Regular Service Work72
Tab. 48 Oil Change Intervals Lubricants72
Cooler: Cleaning or Renewing the Filter Mats73
Fig. 24 Filter Mat for the Air and Oil Cooler73
Tab. 49 Regular Service Work73
Cleaning or Replacing the Control Cabinet Filter Mats74
Cooler Maintenance74
Fig. 25 Control Cabinet Ventilation Grill74
Heat Recovery System Maintenance75
Fig. 26 Cleaning the Cooler75
External Heat Recovery76
Internal Heat Recovery76
Air Filter Maintenance76
Motor Maintenance77
Fig. 27 Air Filter Maintenance77
Checking the Coupling78
Fig. 28 Checking the Coupling78
Checking the Safety Relief Valve79
Checking the Overheating Safety Shutdown Function79
Checking the Cooling Oil Level79
Venting the Machine (Depressurizing)80
Fig. 29 Checking the Cooling Oil Level80
Fig. 30 Venting the Machine81
Topping up the Cooling Oil82
Venting the Machine (Depressurizing)82
Fig. 31 Topping up the Cooling Oil82
Top up with Cooling Oil and Test Run83
Changing the Cooling Oil84
Fig. 32 Changing the Cooling Oil, Oil Separator Tank85
Fig. 33 Changing the Cooling Oil, Oil Cooler86
Fig. 34 Changing the Cooling Oil, Airend87
Changing the Oil Filter88
Fig. 35 Changing the Cooling Oil, Heat Recovery System88
Changing the Oil Separator Cartridge89
Fig. 36 Changing the Oil Filter89
Fig. 37 Changing the Oil Separator Cartridge90
Refrigeration Dryer Maintenance91
Cleaning the Refrigerant Condenser91
Fig. 38 Refrigeration Dryer91
Checking Condensate Drainage92
Condensate Drain Maintenance92
Fig. 39 Checking Condensate Drainage92
Fig. 40 Condensate Drain Maintenance93
Document Maintenance and Service Work94
Tab. 50 Logged Maintenance Tasks94
11 Spares, Operating Materials, Service95
Note the Nameplate95
Ordering Consumable Parts and Operating Materials95
Sigma Air Service95
Tab. 51 Consumable Parts95
Service Addresses96
Spare Parts for Service and Repair96
12 Decommissioning, Storage and Transport99
Putting out of Operation99
Packing99
Storage99
Transporting100
Safety100
Transporting with a Forklift100
Transporting with a Crane100
Fig. 41 Transporting with a Forklift100
Disposal101
Fig. 42 Transporting with a Crane101
13 Annex102
Pipeline and Instrument Flow Diagram (P+I Diagram)102

KAESER ASD T Series - Page 6

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