KAESER TG 450 - User Manual

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Operator Manual

Refrigerated Dryer

No.: 901760 02 USE

Manufacturer:

KAESER KOMPRESSOREN SE

96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130

www.kaeser.com

Main Page

Table of Contents3
Regarding this Document Using this Document11
Further Documents11
Copyright11
Symbols and Labels11
Warnings11
Tab. 1 Danger Levels and Their Definition (Personal Injury)11
Potential Damage Warnings12
Other Alert Notes and Their Symbols12
Tab. 2 Danger Levels and Their Definition (Damage to Property)12
Technical Data Nameplate14
Tab. 3 Machine Nameplate14
Options15
Weight15
Fig. 1 Heat Exchanger Nameplate15
Tab. 4 Options15
Ambient Conditions16
Compressed Air System16
Tab. 5 Weight16
Tab. 6 Ambient Conditions16
Tab. 7 Compressed Air System16
Refrigerant Circuit17
MODBUS TCP Communications Module17
Tab. 8 Refrigerant Circuit17
Water Cooling18
Tab. 9 Communication Interface18
Water-Cooling19
Tab. 10 Design Data for the Cooling System19
Tab. 11 Component Specifications (Option K2)19
Sound Pressure Level20
Power Supply20
Tab. 12 Cooling Water Quality20
Tab. 13 Sound Pressure Level20
Power Supply Specifications21
Fig. 2 Three-Phase (Wye System); 4 Wire; Center Point Solidly Grounded21
Fig. 3 Three-Phase (Wye System); 3 Wire; Center Point Solidly Grounded21
Tab. 14 Performance Data (Option K1)22
Tab. 15 Performance Data (Option K2)22
Tab. 16 Power Supply Details 460V / 3 / 60Hz22
Safety and Responsibility Basic Instructions23
Specified Use23
Improper Use23
User's Responsibilities23
Observe Statutory and Universally Accepted Regulations23
Qualified Personnel24
Dangers24
Safely Dealing with Sources of Danger24
Safe Machine Operation26
Organizational Measures28
Danger Areas28
Safety Devices28
Safety Signs28
Tab. 17 Danger Areas28
Fig. 4 Location of Safety Signs29
Tab. 18 Safety Signs29
Emergency Situations30
Correct Fire Fighting30
Treating Injuries from Handling Refrigerant30
Warranty31
Environment Protection31
Design and Function32
Enclosure32
Machine Function32
Fig. 5 Enclosure Overview32
Fig. 6 Machine Overview33
Operating Points and Control Modes34
Machine Operating Modes34
Secotec Control34
Electronic Condensate Drain34
Condensate Drain Operating States35
Safety Devices35
Floating Contacts35
Tab. 19 Indication of the Operational State of the Condensate Drain35
Sigma Control Smart36
Operating Panel36
Fig. 7 Keys - Overview36
Tab. 20 Keys (Mechanical)36
Fig. 8 Keys (Soft Key)37
Fig. 9 Indicators37
Tab. 21 Keys (Soft Key)37
User Operation SIGMA CONTROL SMART38
Tab. 22 Indicators38
Tab. 23 Handling Concept38
Fig. 10 Main Menu39
Tab. 24 Main Menu39
Tab. 25 Color Concept39
Start Screen40
Messages Menu40
Fig. 11 Start Screen40
Fig. 12 Event History40
Flow Diagram" Menu41
Information" Menu41
Fig. 13 Flow Diagram41
Fig. 14 Information: Screen42
Fig. 15 Information: Screen42
Service Menu43
Fig. 16 Information: Screen 343
Fig. 17 Screen 1: Condensate Drain44
Fig. 18 Screen 2: Refrigerant Condenser44
MODBUS TCP Communication Module45
Display and Operating Elements of the Communications Module45
Fig. 19 Installation Variant with SIGMA AIR MANAGER45
Fig. 20 Operating Elements, Displays and Connections of the Communications Module46
Tab. 26 Plug-In Communications Module - Operating Elements, Displays and Connections46
Options47
Floating Contact "Refrigerated Compressor Runs47
Pressure Dew Point Warning47
Machine Mountings47
Water-Cooling47
Fig. 21 Machine Mountings47
Accessories48
Transformer48
Fig. 22 Water-Cooling48
Installation and Operating Conditions49
Ensuring Safety49
Installation Conditions49
Determining Location and Clearances49
Ensuring the Machine Room Ventilation50
Fig. 23 Recommended Machine Placement and Dimensions [In]50
Exhaust Air Duct Design51
Operating the Machine in a Compressed Air Network51
Installation52
Ensuring Safety52
Reporting Transport Damage53
Creating the Air Connection53
Fig. 24 Air Connection53
Connecting the Condensate Drain54
Tab. 27 Condensate Line54
Tab. 28 Condensate Collecting Line54
Connecting the Machine to the Power Supply55
Fig. 25 Connecting the Condensate Drain55
Tab. 29 Condensate Collecting Line: Line Diameter55
Connecting the MODBUS TCP Communications Module with SIGMA AIR MANAGER56
Communication with SIGMA AIR MANAGER 4.056
Communication with the User's (Central) Control System56
Options56
Anchoring the Machine56
Connecting the Water Cooling56
Fig. 26 Connecting the Water Cooling57
Initial Start-Up Ensuring Safety58
Instructions to be Observed before Commissioning or Re-Commissioning59
Checking Installation and Operating Conditions59
Tab. 30 Re-Commissioning after Storage59
Starting the Machine for the First Time60
Registering the Machine at the Bus60
Tab. 31 Installation Conditions Checklist60
Operation62
Switching the Machine on and off62
Switching on62
Fig. 27 Switching the Machine on and off62
Switching off63
Using the Remote Control63
Switching the Remote Control on and off63
Fig. 28 Switching the Remote Control on and off63
Acknowledging and Resetting Warning and Alarm Messages64
Fig. 29 Acknowledging Messages64
Fault Recognition and Rectification65
Basic Instructions65
Messages at the Controller65
Communications Module - Troubleshooting66
Tab. 32 Alarm Messages66
Tab. 33 Warning Messages66
Tab. 34 Maintenance Messages66
Fig. 30 Displays and Connections of the Communications Module67
Tab. 35 Fault Messages on the Communications Module67
Faults68
Tab. 36 Faults and Troubleshooting68
10.1 Maintenance69
Ensuring Safety69
Regular Maintenance Tasks70
Cleaning the Refrigerant Condenser70
Tab. 37 Regular Maintenance Tasks70
Tab. 38 Regular Maintenance Tasks70
Air-Cooling Maintenance71
Water-Cooling Maintenance71
Fig. 31 Clean the Refrigerant Condenser71
Maintaining the Condensate Drain72
Checking the Condensate Drain72
Replacing the Service Unit72
Fig. 32 Checking the Condensate Drain72
Fig. 33 Replacing the Service Unit73
11 Spares, Operating Materials, Service75
Note the Nameplate75
Consumable Parts and Operating Materials75
Kaeser Air Service75
Replacement Parts for Service and Repair75
Tab. 39 Consumable Parts75
12.1 Decommissioning, Storage and Transport87
Decommissioning87
Storage87
Transport87
Safety87
Transport with a Forklift Truck88
Transport with a Crane88
Fig. 34 Transporting with a Forklift Truck88
Disposal89
Fig. 35 Transport with a Crane89
13 Annex91
Dimensional Drawing91
Pipeline and Instrument Flow Diagram (P+I Diagram)95
Electrical Diagram98

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KAESER TG 450 Specifications

General

Brand	KAESER
Model	TG 450
Category	Dryer
Language	English

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KAESER TG 450 - User Manual

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