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KAESER
Air Compressor
ASK 32
KAESER ASK 32 Service Manual
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10.19
Documenting maintenance and service work
Machine number:
➤
Enter maintenance and service work carried out in the list.
Date
Maintenance task carried out
Operating hours
Signature
Tab. 56
Logged maintenance tasks
10
Maintenance
10.19
Documenting maintenance and service work
9_5717 20 E
Service Manual Screw Compressor
ASK T SIGMA CONTROL BASIC
83
92
94
Table of Contents
Default Chapter
3
Table of Contents
3
1 Regarding this Document Using this Document
11
Using this Document
11
Further Documents
11
Copyright
11
Symbols and Labels
11
Warnings
11
Tab. 1 Danger Levels and Their Definition (Personal Injury)
11
Potential Damage Warnings
12
Other Alerts and Their Symbols
12
Tab. 2 Danger Levels and Their Definition (Damage to Property)
12
2 Technical Specifications Nameplate
14
Options
14
Weight
14
Tab. 3 Nameplate
14
Tab. 4 Options
14
Temperature
15
Ambient Conditions
15
Tab. 5 Machine Weight
15
Tab. 6 Temperature
15
Tab. 7 Ambient Conditions
15
Ventilation
16
Pressure
16
Fig. 1 Maximum Relative Humidity of Intake Air
16
Tab. 8 Overview Ventilation (50Hz)
16
Tab. 9 Overview Ventilation (60Hz)
16
Delivery
17
Tab. 10 Pressure Relief Valve Activating Pressure (50Hz)
17
Tab. 11 Pressure Relief Valve Activating Pressure (60Hz)
17
Tab. 12 Delivery (50 Hz)
17
Tab. 13 Delivery (60 Hz)
17
Noise Emission [Db(A)]
18
Motors and Power
18
Drive Motor
18
Cooling Oil Recommendation
18
Tab. 14 Noise Emission [Db(A)]
18
Tab. 15 Drive Motor
18
Tab. 16 Drive Motor: Nominal Speed at 50 Hz
18
Tab. 17 Drive Motor: Nominal Speed at 60 Hz
18
Tab. 18 Cooling Oil Recommendation
19
Cooling Oil Charge
20
Tab. 19 Cooling Oil Recommendation (Food Processing)
20
Tab. 20 Cooling Oil Recommendation (Machines for Snow Cannons)
20
Tab. 21 Cooling Oil Charge (Option K1)
20
Power Supply
21
Power Supply Specifications
21
Tab. 22 Cooling Oil Charge (Option W1)
21
Mains Frequency: 50 Hz
22
Tab. 23 Mains Supply 200V/3/50Hz
22
Tab. 24 Mains Supply 230V/3/50Hz
22
Tab. 25 Mains Supply 400V/3/50Hz
22
Mains Frequency: 60 Hz
23
Tab. 26 Supply Conditions at 400V/3/50Hz
23
Tab. 27 Mains Supply 230V/3/60Hz
23
Tab. 28 Mains Supply 380V/3/60Hz
23
Tab. 29 Mains Supply 440V/3/60Hz
23
Available Heat Capacity
24
Refrigeration Dryers
24
Tab. 30 Mains Supply 460V/3/60Hz
24
Tab. 31 Heat Capacity (Option W1)
24
Tab. 32 Refrigeration Dryer: Model
24
Tab. 33 Refrigeration Dryer: Compressed Air System
24
Tab. 34 Refrigeration Dryer: Refrigerant Circuit
25
3 Safety and Responsibility Basic Instructions
26
Specified Use
26
Improper Use
26
User's Responsibilities
26
Observe Statutory and Universally Accepted Regulations
26
Qualified Personnel
27
Adhere to Inspection Schedules and Accident Prevention Regulations
27
Dangers
28
Safely Dealing with Sources of Danger
28
Tab. 35 Inspection Intervals According to Regulations
28
Safe Machine Operation
30
Organisational Measures
32
Danger Areas
32
Safety Devices
33
Safety Signs
33
Fig. 2 Location of Safety Signs
33
Tab. 36 Danger Areas
33
Emergency Situations
34
Correct Fire Fighting
34
Tab. 37 Safety Signs
34
Treating Injuries from Handling Cooling Oil
35
Injury from Handling Refrigerant
35
Warranty
36
Environment Protection
36
4 Design and Function
37
Enclosure
37
Fig. 3 Enclosure Overview
37
Machine Function
38
Fig. 4 Machine Layout
38
Refrigeration Dryer
39
Floating Relay Contacts
39
Options
39
Machine Mountings
39
Fig. 5 Refrigeration Dryer
39
Fig. 6 Machine Mountings
39
Prepared for External Heat Recovery
40
Operating Modes and Control Modes
40
Operating Modes
40
Control Modes
41
Tab. 38 Energy-Efficient Control Modes
41
Refrigeration Dryer Control Modes
42
Tab. 39 Operating Modes under MODULATING Control
42
Tab. 40 Refrigeration Dryer Control Modes
42
Safety Devices
43
Keys and Leds - SIGMA CONTROL BASIC
43
Fig. 7 Keys - Overview
43
Functional Description - SIGMA CONTROL BASIC
44
Display Layout
44
Fig. 8 Indicators
44
Tab. 41 Keys
44
Tab. 42 Indicators
44
Parameters
45
Tab. 43 Display
45
Messages
46
Tab. 44 Parameters
46
5 Installation and Operating Conditions
47
Ensuring Safety
47
Installation Conditions
47
Determining Location and Clearances
47
Ensuring the Machine Room Ventilation
48
Fig. 9 Recommended Machine Placement and Dimensions [MM]
48
Exhaust Duct Design
49
Operating the Machine in a Compressed Air Network
49
6 Installation
50
Ensuring Safety
50
Installation 6.1 Ensuring Safety
50
Reporting Transport Damage
51
Connecting the Machine with the Compressed Air Network
51
Connecting the Power Supply
51
Fig. 10 Compressed Pipework
51
Refrigeration Dryer: Connecting the Transformer According to the Mains Supply
52
Connecting the Condensate Drain
52
Connecting the Remote LOAD-IDLE Control
53
Fig. 11 Condensate Drain Dimensions [MM]
53
Fig. 12 Connections SIGMA CONTROL BASIC
53
Options
54
Anchoring the Machine
54
Connecting the External Heat Recovery System
54
7 Initial Start-Up Ensuring Safety
55
Instructions to be Observed before Commissioning or Re-Commissioning
56
Checking Installation and Operating Conditions
56
Tab. 45 Re-Commissioning after Storage
56
Setting the Overload Protection Cut-Out
57
Pouring Cooling Oil into the Airend
57
Tab. 46 Installation Conditions Checklist
57
Activating and Deactivating the MODULATING Control
58
Fig. 13 Inlet Valve Filling Port
58
Tab. 47 MODULATING Control: Setting the Shut-Off Valve
58
Checking the Door Interlock Switch
59
Fig. 14 MODULATING Control: Setting the Shut-Off Valve
59
Fig. 15 Location of the Interlock Switch
59
Starting the Machine for the First Time
60
Setting the Setpoint Pressure
60
8 Operation
62
Switching on and off
62
Switching on
62
Switching off
62
Fig. 16 Switching on and off
62
Operation 8.1 Switching on and off
62
Switching off in an Emergency and Switching on Again
63
Fig. 17 Switching off in an Emergency
63
Tab. 48 Switching off With/Without Run-On Time
63
Setting Parameters
64
Acknowledging Alarm and Warning Messages
65
Fig. 18 Acknowledging Messages
65
9 Fault Recognition and Rectification
66
Basic Instructions
66
Alarm Messages (Machine Shut Down)
66
Warning Messages
67
Tab. 49 Alarm Indications
67
Tab. 50 Warning Messages
67
Other Faults
68
Tab. 51 Other Faults and Actions
68
10 1 Maintenance
69
Ensuring Safety
69
Following the Maintenance Plan
70
Logging Maintenance Work
70
Resetting Maintenance Interval Counters
70
Regular Maintenance Tasks
70
Tab. 52 Regular Maintenance Tasks
70
Cooling Oil: Change Interval
71
Regular Service Tasks
72
Cooler: Cleaning or Renewing the Filter Mats
72
Tab. 53 Cooling Oil: Change Intervals
72
Tab. 54 Regular Service Tasks
72
Control Cabinet: Clean or Renew the Filter Mat
73
Fig. 19 Filter Mat for the Air and Oil Cooler
73
Cooler Maintenance
74
Fig. 20 Switching Cabinet Ventilation
74
Maintaining the External Heat Recovery System
75
Fig. 21 Filter Mat for the Air and Oil Cooler
75
Air Filter Maintenance
76
Compressor Motor Maintenance
76
Fig. 22 Air Filter Maintenance
76
Maintaining the Drive Belts
77
Fig. 23 Drive Belt Maintenance
77
Testing the Pressure Relief Valve
78
Checking the Excess Temperature Safety Shutdown Function
79
Checking the Cooling Oil Level
79
Venting the Machine (De-Pressurising)
80
Fig. 24 Checking the Cooling Oil Level
80
Fig. 25 Venting the Machine
81
Replenishing the Cooling Oil
82
Venting the Machine (De-Pressurising)
82
Fig. 26 Replenishing the Cooling Oil
82
Topping up with Cooling Oil and Trial Run
83
Changing the Cooling Oil
84
Fig. 27 Changing the Cooling Oil, Oil Separator Tank
85
Fig. 28 Changing the Cooling Oil, Heat Recovery System
86
Changing the Oil Filter
87
Fig. 29 Changing the Oil Filter
87
Changing the Oil Separator Cartridge
88
Fig. 30 Changing the Oil Separator Cartridge
89
Refrigeration Dryer Maintenance
90
Cleaning the Refrigerant Condenser
90
Checking the Condensate Drain
90
Fig. 31 Refrigeration Dryer
90
Condensate Drain Maintenance
91
Fig. 32 Checking Condensate Drainage
91
Fig. 33 Condensate Drain Maintenance
92
Documenting Maintenance and Service Work
93
11 Spares, Operating Materials, Service
94
Note the Nameplate
94
Ordering Consumable Parts and Operating Fluids/Materials
94
Kaeser Air Service
94
Service Addresses
95
Spare Parts for Service and Repair
95
12 Decommissioning, Storage and Transport
100
Putting out of Operation
100
Packing
100
Storage
100
Transport
101
Safety
101
Transport with a Forklift Truck
101
Transport with a Crane
101
Fig. 34 Transport with a Forklift Truck
101
Disposal
102
Fig. 35 Transport with a Crane
102
13 Annex
103
Pipeline and Instrument Flow Diagram (P+I Diagram)
103
Pipeline and Instrument Flow Diagram (P&I Diagram) MODULATING Control
109
Dimensional Drawing
115
Electrical Diagram
118
4
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KAESER ASK 32 Specifications
General
Brand
KAESER
Model
ASK 32
Category
Air Compressor
Language
English
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