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KAESER ESD 442 SFC User Manual

KAESER ESD 442 SFC
413 pages
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Project: Florence12 / L.00478
Order-No.: 10357405
Technical Documentation
Compressor-Typ: ESD 442 SFC / 14 bar (a), ac, Helium
Compressor-No.: ESD.2C / Serial-No.: 1205
Table of Contents
1.
Dimensional drawing
2.
Electrical diagram
3.
Service manual compressor
4.
Service manual Sigma Control
5.
Spare Parts List
6.
Performance test by helium #100714
7.
Measurement record for units with suction side gas
supply
8.
Quality-Dimensions-Material-Surface #100713

Table of Contents

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KAESER ESD 442 SFC Specifications

General IconGeneral
ModelESD 442 SFC
CategoryAir Compressor
Power45 kW
Motor Power45 kW
Voltage400 V
Frequency50 Hz
TypeRotary Screw Compressor
Dimensions2420 x 2000 x 2150 mm
Drive TypeDirect Drive
Dimensions (LxWxH)2420 x 2000 x 2150 mm

Summary

3 Safety and Responsibility

3.1 Basic instructions

Highlights that dangers can arise from operation and emphasizes using the machine in a technically perfect condition.

3.5 Dangers

Describes various forms of danger during machine operation, including electricity, compression forces, and rotating components.

3.6 Safety devices

Emphasizes that safety devices ensure safe working and should not be changed, bypassed, or disabled.

3.8 In emergency

Provides guidance on dealing with emergencies, including correct fire fighting procedures and treating injuries.

4 Design and Function

4.8 Safety Devices

Lists provided safety devices like EMERGENCY STOP, pressure relief valve, and guards, stating they cannot be changed.

4.9 Operating panel SIGMA CONTROL 2

Provides an overview of the operating panel, including keys and their functions for controlling the machine.

Indicators

Explains the various indicators on the operating panel and their functions, such as Alarm, Warning, and LOAD status.

5 Installation and Operating Conditions

5.1 Ensuring safety

Emphasizes that installation and operating conditions significantly affect safety and warns against disregarding safety notes.

6 Installation

6.1 Ensuring safety

Provides instructions for safe installation, emphasizing authorized personnel and safety measures for live components and pressure systems.

6.5 Connecting the power supply

Provides detailed instructions for connecting the power supply, emphasizing authorized personnel and safety measures.

7 Initial Start-up

7.2 Configuring the controller

Details the process of configuring the controller, including menu options, display language, and access rights.

7.4 Adjusting the pressure parameters of the machine

Provides instructions for displaying and adjusting pressure parameters like setpoint pressure and system pressure low.

7.5 Configuring machine start and stop

Outlines alternatives for machine start and stop, including automatic clock mode, holidays, and remote control.

7.6 Activating and adjusting the control modes

Explains various control modes (DUAL, QUADRO, VARIO, DYNAMIC, CONTINUOUS) and how to adjust their settings.

7.8 Configuring the machine for local mode

Explains how to configure the machine for local mode, including pressure setpoint changeover using clock programs.

7.9 Configuring the machine for master control

Describes methods for configuring master control, including Profibus, Ethernet, LOAD remote contact, and pressure switch regulation.

7.11 Configuring input and output signals

Details how to use binary and analog inputs/outputs for various requirements, including assigning messages and displaying data.

7.14 Commissioning the machine

Provides a checklist for verifying controller settings before starting the machine.

8 Operation

8.1 Switching on and off

Details the procedure for switching the machine on and off using the ON/OFF keys and power supply.

8.2 Switching off in an emergency and switching on again

Explains how to use the EMERGENCY STOP button and the procedure for switching the machine on again after an emergency stop.

8.3 Acknowledging alarm and warning messages

Describes how to acknowledge alarm and warning messages using the controller's LEDs and keys.

8.4 Displaying messages

Explains how to access and interpret current messages, message history, compressor, diagnostic, and system messages.

8.6 Adjusting working pressure

Provides guidance on adjusting the pressure parameter to suit the compressor and application requirements.

8.9 Setting the maintenance interval

Explains how to change service intervals for components like oil filter and oil separator.

8.10 Safety relief valve checking

Provides a step-by-step guide for testing the safety relief valve, including preparing, performing, and concluding the test.

8.11 Checking the temperature sensor and overheating shutdown function

Describes how to check the temperature sensor and overheating shutdown function by simulating a higher temperature.

9 Fault Recognition and Rectification

9.2 Interpreting alarm messages

Lists alarm messages identified by 'A', detailing possible causes and remedies for faults like direction of rotation or motor temperature.

10 Maintenance

10.1 Maintenance Work

States that SIGMA CONTROL 2 and I/O modules are maintenance-free and emphasizes basic safety instructions.

10.11 Checking the pressure relief valve

Details the procedure for checking the pressure relief valve by raising working pressure above its activating pressure.

10.12 Checking the overheating safety shutdown function

Explains how to check the temperature sensor and overheating shutdown function by simulating a higher temperature.

10.16 Changing the cooling oil

Provides instructions for draining cooling oil from the oil separator tank, oil cooler, and compressor block, and changing filters.

10.17 Changing the oil filter

Explains how to change the oil filter, including safety warnings and the trial run procedure.

10.18 Changing the oil separator cartridge

Describes the process for changing the oil separator cartridge, noting it cannot be cleaned and its life is influenced by gas contamination.

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