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KAESER
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ASK 40
KAESER ASK 40 User Manual
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Operating Manual
Screw Compressor
ASK
901824 12 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
2
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
Tab. 3 Nameplate
14
Tab. 4 Options
14
Mass
15
Temperature
15
Ambient Conditions
15
Tab. 5 Mass
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
Flow Rate (Constant Delivery Volume Relative to Intake Conditions)
17
Tab. 10 Pressure Relief Valve Activating Pressure (50Hz)
17
Tab. 11 Pressure Relief Valve Activating Pressure (60Hz)
17
Tab. 12 Flow Rate (50Hz)
17
Tab. 13 Flow Rate (60 Hz)
17
Cooling Oil Recommendation
18
Tab. 14 Cooling Oil Recommendation
18
Cooling Oil Charge Quantity
19
Tab. 15 Cooling Oil Recommendation (Food Processing)
19
Tab. 16 Cooling Oil Recommendation (Machines for Snow Cannons)
19
Motors and Power
20
Compressor Drive Motor
20
Tab. 17 Cooling Oil Charge Quantity
20
Tab. 18 Cooling Oil Charge (Option W2)
20
Tab. 19 Cooling Oil Charge (Option W3)
20
Tab. 20 Compressor Drive Motor
20
Tab. 21 Compressor Drive Motor: Rated Speed for 50 Hz
20
Fan Motor
21
Noise Emission [Db(A)]
21
Electrical Connection
21
Tab. 22 Compressor Drive Motor: Rated Speed for 60 Hz
21
Tab. 23 Fan Motor (50Hz)
21
Tab. 24 Fan Motor (60Hz)
21
Tab. 25 Noise Emission [Db(A)]
21
Power Supply Specifications
22
Mains Frequency: 50 Hz
22
Tab. 26 Supply Details 200V / 3 / 50Hz
22
Mains Frequency: 60 Hz
23
Tab. 27 Supply Details 230V / 3 / 50Hz
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Tab. 28 Supply Details 400V / 3 / 50Hz
23
Tab. 29 Network Conditions at 400V / 3 / 50Hz
23
Heat Recovery
24
Tab. 30 Supply Details 230V / 3 / 60Hz
24
Tab. 31 Supply Details 380V / 3 / 60Hz
24
Tab. 32 Supply Details 440V / 3 / 60Hz
24
Tab. 33 Supply Details 460V / 3 / 60Hz
24
Tab. 34 Heat Recovery: Individual Design Data
25
Tab. 35 Specification: Heat Exchanger (Option W2/W3)
25
Tab. 36 Quality of the Heat Receiving Medium
26
Tab. 37 Heat Capacity (Option W2/W3)
26
Tab. 38 Flow Rate / Pressure Drop (Option W2)
26
Tab. 39 Flow Rate / Pressure Drop (Option W3)
27
3 Safety and Responsibility Basic Instructions
28
Specified Use
28
Improper Use
28
User's Responsibilities
28
Observe Statutory and Universally Accepted Regulations
28
Determining Personnel
29
Keeping to Inspection Schedules and Accident Prevention Regulations
29
Dangers
30
Safely Dealing with Sources of Danger
30
Tab. 40 Inspection Intervals According to Ordinance on Industrial Safety and Health
30
Safe Machine Operation
32
Organisational Measures
34
Danger Areas
34
Safety Devices
35
Service Life of Safety Functions
35
Tab. 41 Danger Areas
35
Tab. 42 Category and Performance Level
35
Safety Signs
36
Fig. 2 Location of Safety Signs
36
Emergency Situations
37
Correct Fire Fighting
37
Treating Injuries from Handling Cooling Oil
37
Tab. 43 Safety Signs
37
Warranty
38
Environment Protection
38
4 Design and Function
39
Housing
39
Fig. 3 Housing Overview
39
Machine Function
40
Safety Devices
40
Fig. 4 Machine Layout
40
Floating Relay Contacts
41
Operating Panel SIGMA CONTROL
41
Fig. 5 Keys - Overview
41
Fig. 6 Indicators - Overview
42
Tab. 44 Keys
42
Fig. 7 RFID Reader
43
Tab. 45 Leds
43
Tab. 46 RFID Reader
43
Operating Modes and Control Modes
44
Machine Operating Modes
44
Control Modes
44
Tab. 47 Energy-Saving Control Modes
45
Options
46
SIGMA CONTROL 2 Controller: Connection to Control Technology
46
Machine Mountings
46
Heat Recovery
46
Fig. 8 Machine Mountings
46
Tab. 48 Components
46
Fig. 9 Function of the Heat Recovery
47
5 Installation and Operating Conditions
48
Ensuring Safety
48
Installation Conditions
48
Determining Location and Clearances
48
Ensuring the Machine Room Ventilation
49
Fig. 10 Recommended Machine Placement and Dimensions [MM]
49
Exhaust Duct Design
50
Operating the Machine in a Compressed Air Network
50
6 Installation
51
Ensuring Safety
51
Reporting Transport Damage
52
Connecting the Machine with the Compressed Air Network
52
Connecting the External Pressure Transducer
52
Fig. 11 Compressed Air Pipework
52
Connecting the Machine with the Power Supply
53
Options
54
Anchoring the Machine
54
Connecting the Heat Recovery System
54
Fig. 12 Connecting the Heat Recovery System
54
7 Initial Start-Up Ensuring Safety
56
Instructions to be Observed before Commissioning
57
Checking Installation and Operating Conditions
57
Tab. 49 Re-Commissioning after Storage
57
Setting the Overload Protection Cut-Out
58
Setting the Motor Overload Protection Switch
58
Pouring Cooling Oil into the Airend
58
Tab. 50 Installation Conditions Checklist
58
Activating and Deactivating the MODULATING Control
59
Fig. 13 Airend Filling Port
59
Tab. 51 Activating and Deactivating the MODULATING Control
59
Starting the Machine for the First Time
60
Fig. 14 Activating and Deactivating the MODULATING Control
60
Setting the Set Point Pressure
61
Setting the Display Language
61
8 Operation
62
Switching on and off
62
Switching on
62
Switching off
62
Fig. 15 Switching on and off
62
Switching off in an Emergency and Switching on Again
63
Using the Remote Control for Switching on and off
63
Fig. 16 Switching off in an Emergency
63
Using the Timer for Switching on and off
64
Fig. 17 Using the Remote Control for Switching on and off
64
Tab. 52 Machine Identification
64
Tab. 53 Remote Control Identification
64
Interpreting Operation Messages
65
Acknowledging Alarm and Warning Messages
65
Fig. 18 Using the Timer for Switching on and off
65
Tab. 54 Machine Identification
65
Fig. 19 Acknowledging Messages
66
9 Fault Recognition and Rectification
67
Basic Instructions
67
Other Faults
67
Tab. 55 Other Faults and Remedies
68
10 1 Maintenance
69
Ensuring Safety
69
Tab. 56 Advise Others that the Machine Is Being Serviced
69
Following the Maintenance Plan
70
Logging Maintenance Work
70
Resetting Maintenance Interval Counters
70
Regular Maintenance Tasks
70
Cooling Oil Change Interval
71
Tab. 57 Regular Maintenance Tasks
71
Regular Service Tasks
72
Tab. 58 Cooling Oil Change Intervals
72
Tab. 59 Regular Service Tasks
72
Cooler: Cleaning or Renewing the Filter Mats
73
Control Cabinet: Clean or Renew the Filter Mat
73
Fig. 20 Filter Mat for the Air and Oil Cooler
73
Cooler Maintenance
74
Fig. 21 Switching Cabinet Ventilation
74
Maintain the Heat Recovery System
75
Fig. 22 Filter Mat for the Air and Oil Cooler
75
Air Filter Maintenance
76
Motor Maintenance
76
Fig. 23 Air Filter Maintenance
76
Drive Belt Maintenance
77
Fig. 24 Drive Belt Maintenance
77
Testing the Pressure Relief Valve
78
Check the Safety Shut-Down Due to Excessive Airend Discharge Temperature
79
Check the EMERGENCY STOP Control Device
79
Checking the Cooling Oil Level
79
Fig. 25 Check the EMERGENCY STOP Control Device
79
Venting the Machine (De-Pressurising)
80
Fig. 26 Checking the Cooling Oil Level
80
Fig. 27 Venting the Machine
81
Replenish Cooling Oil
82
Venting the Machine (De-Pressurising)
82
Fig. 28 Replenish Cooling Oil
82
Topping up with Cooling Oil and Trial Run
83
Changing the Cooling Oil
84
Fig. 29 Changing the Cooling Oil, Pressuring the Oil Separator Tank
85
Fig. 30 Changing the Cooling Oil Oil Separator Tank
86
Fig. 31 Changing the Cooling Oil Oil Cooler
86
Fig. 32 Changing the Cooling Oil Compressor Block
87
Fig. 33 Changing the Cooling Oil Heat Recovery
88
Fig. 34 Changing the Cooling Oil Filling with Cooling Oil
88
Changing the Oil Filter
89
Fig. 35 Changing the Oil Filter
89
Changing the Oil Separator Cartridge
90
Fig. 36 Changing the Oil Separator Cartridge
91
Documenting Maintenance and Service Work
93
Tab. 60 Logged Maintenance Tasks
93
11 Spares, Operating Materials, Service
94
Note the Nameplate
94
Ordering Consumable Parts and Operating Fluids/Materials
94
Kaeser Air Service
94
Tab. 61 Consumable Parts
94
Replacement Parts for Service and Repair
95
12 1 Decommissioning, Storage and Transport
98
Commissioning
98
Temporary De-Commissioning
98
Long-Term De-Commissioning
98
Packing
99
Storage
99
Transport
99
Safety
99
Transport with a Forklift Truck
99
Transport with a Hoist
100
Fig. 37 Transporting with a Forklift Truck
100
Fig. 38 Transporting with a Crane
101
Disposal
102
Dispose of the Battery in Accordance with Local Environmental Regulations
102
Fig. 39 Battery Labelling
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
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KAESER ASK 40 Specifications
General
Model
ASK 40
Category
Rotary Screw Compressor
Motor Power
22 kW
Noise Level
68 dB(A)
Type
Rotary Screw
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