KAESER ASK T series, Service Manual

Page 1: ...Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E Manufacturer KAESER KOMPRESSOREN GmbH 96410 Coburg PO Box 2143 GERMANY Tel 49 0 9561 6400 Fax 49 0 9561 640130 http www kaeser com...

Page 2: ...Original instructions KKW SASK 2 00 en SBA SCHRAUBEN T SCB 20111103 144508...

Page 3: ...n dryers 14 3 Safety and Responsibility 3 1 Basic instructions 16 3 2 Specified use 16 3 3 Improper use 16 3 4 User s Responsibilities 16 3 4 1 Observe statutory and universally accepted regulations 1...

Page 4: ...efrigeration dryer Connecting the transformer according to the mains supply 42 6 5 Connecting the Condensate Drain 42 6 6 Connecting the remote LOAD IDLE control 43 6 7 Options 44 6 7 1 Anchoring the...

Page 5: ...ssurising 72 10 14 2 Topping up with cooling oil and trial run 73 10 15 Changing the cooling oil 74 10 16 Changing the oil filter 77 10 17 Changing the oil separator cartridge 78 10 18 Refrigeration D...

Page 6: ...13 4 Electrical Diagram 108 Contents iv Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 7: ...g 18 Acknowledging messages 55 Fig 19 Filter mat for the air and oil cooler 63 Fig 20 Switching cabinet ventilation 64 Fig 21 Filter mat for the air and oil cooler 65 Fig 22 Air filter maintenance 66...

Page 8: ...List of Illustrations vi Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 9: ...pply conditions at 400V 3 50Hz 13 Tab 27 Mains supply 230V 3 60Hz 13 Tab 28 Mains supply 380V 3 60Hz 13 Tab 29 Mains supply 440V 3 60Hz 13 Tab 30 Mains supply 460V 3 60Hz 13 Tab 31 Heat capacity optio...

Page 10: ...ab 55 Permissible cooling oil level under LOAD 69 Tab 56 Logged maintenance tasks 83 Tab 57 Consumable parts 84 List of Tables viii Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20...

Page 11: ...data from the nameplate when ordering documents 1 3 Copyright This service manual is copyright protected Queries regarding use or duplication of the documenta tion should be referred to KAESER Correc...

Page 12: ...ger are shown here 2 Always read and comply with warning instructions 1 4 2 Potential damage warnings Contrary to the warnings shown above damage warnings do not indicate a potential personal in jury...

Page 13: ...n relating to one option only are marked with an option code e g H1 indicates that this section applies only to machines with screw in machine feet Option codes used in this service manual are explain...

Page 14: ...imum working pressure Ambient temperature Tab 3 Nameplate 2 2 Options The table contains a list of possible options Enter options here as a reference Option Option code Exists Modulating control C1 Ad...

Page 15: ...ut down C 110 110 110 Tab 6 Temperature 2 5 Ambient conditions ASK 27 ASK 32 ASK 35 Maximum elevation amsl m 1000 1000 1000 Permissible ambient tem perature C 3 45 3 45 3 45 Cooling air temperature C...

Page 16: ...d ventilation with exhaust fan Flow rate m3 h at 100 Pa 7500 8500 9500 Tab 8 Overview Ventilation 50Hz Mains frequency 60 Hz ASK 27 ASK 32 ASK 35 Inlet aperture Z see fig ure 9 m2 0 6 0 6 0 7 Forced v...

Page 17: ...13 13 15 0 16 16 16 Tab 11 Pressure relief valve activating pressure 60Hz 2 8 Delivery Delivery m3 min at 50 Hz mains frequency Maximum working pres sure bar ASK 27 ASK 32 ASK 35 8 0 2 60 3 15 3 50 1...

Page 18: ...orking pres sure bar ASK 27 ASK 32 ASK 35 8 0 2945 2950 2940 11 0 2945 2950 2940 15 0 2945 2950 2940 Tab 16 Drive motor nominal speed at 50 Hz Rated speed min 1 60 Hz mains frequency Maximum working p...

Page 19: ...ty at 15 C 864 kg m3 ISO 12185 0 869 kg l D 1298 ASTM test Pour point 33 C ISO 3016 46 C D 97 ASTM test 54 C D 97 ASTM test Demulsibility at 54 C 40 40 0 10 min D 1401 ASTM test 15 min D 1401 ASTM tes...

Page 20: ...snow cannons Approval Viscosity at 40 C 47 mm2 s Viscosity at 100 C 8 1 mm2 s Flash point 210 C Density at 15 C 0 92 g ml Pour point 35 C Demulsibility at 54 C Tab 20 Cooling oil recommendation machin...

Page 21: ...aking further measures earth leak detection etc Further requirements Demands on a three phase supply for a machine with the following equipment Refrigeration dryer powered from a transformer This mach...

Page 22: ...pply cable mm2 4x10 4x10 4x10 Current input A 35 38 45 Tab 25 Mains supply 400V 3 50Hz 2 14 1 1 Network conditions The network conditions apply to machines connected to public mains supplies with the...

Page 23: ...0 3 60Hz ASK 27 ASK 32 ASK 35 Backup fuse A 80 80 100 Supply cable mm2 4x25 4x25 4x35 Current input A 64 74 84 Tab 27 Mains supply 230V 3 60Hz Rated voltage 380V 10 3 60Hz ASK 27 ASK 32 ASK 35 Backup...

Page 24: ...Heat capacity option W1 2 16 Refrigeration dryers Model ASK 27 ASK 32 ASK 35 Model Read off the dryer model from the dryer nameplate and enter it in the table Tab 32 Refrigeration dryer Model Compres...

Page 25: ...ximum permitted working pressure bar low pressure end 16 16 Safety pressure switch Cut out pressure bar 21 21 Read off the charge quantity from the dryer nameplate and enter it in the table Tab 34 Ref...

Page 26: ...achine only within its performance limits and under the permitted ambient condi tions Do not use compressed air for breathing purposes unless it is specifically treated Do not use compressed for any a...

Page 27: ...possible dangers of electrical and compressed air devices and take appropriate measures to safeguard persons and property have received adequate training and authorisation for the safe installation a...

Page 28: ...n electric shocks burns or death Allow only qualified and authorised electricians or trained personnel under the supervision of a qualified and authorised electrician to carry out work on electrical e...

Page 29: ...e belt drive while the machine is switched on can result in serious injury Do not open the enclosure while the machine is activated Switch off and lock out the power supply disconnecting device and ve...

Page 30: ...approval by the manufacturer prior to any technical modification or expansion of the machine the controller or the control programs Extending or modifying the compressor station If dimensioned appropr...

Page 31: ...d faults Install the machine in a suitable compressor room Ensure sufficient and suitable lighting such that the display can be read and work carried out comfortably and safely Ensure accessibility so...

Page 32: ...e of any components requiring monitoring Pay particular attention to cleanliness during all maintenance and repair work Cover compo nents and openings with clean cloths paper or tape to keep them clea...

Page 33: ...ger Areas 3 6 Safety devices Various safety devices ensure safe working with the machine Do not change bypass or disable safety devices Regularly check safety devices for their correct function Do not...

Page 34: ...d by an automatic machine start Switch off and lock out the mains isolating devices and verify the absence of any voltage before opening any machine enclosure or guard 5 Risk of fatal injury caused by...

Page 35: ...athing difficult Clear air passages of oil mist Seek medical help if difficulty with respiration continues Ingestion Wash out the mouth immediately Do not induce vomiting Seek medical aid 3 8 3 Injury...

Page 36: ...obligation lies with the user to determine its suitability for his specific application Furthermore we accept no warranty obligation for the use of unsuitable parts or operating materials un authorise...

Page 37: ...components Cooling air flow The enclosure is not suitable for the following uses Walking on standing or sitting on As resting place or storage of any kind of load Safe and reliable operation is only a...

Page 38: ...ompressed air in the oil separator tank 7 gives up its heat in the oil cooler 9 The oil then flows through the oil filter 4 and back to the point of injection Pressure with in the machine keeps the oi...

Page 39: ...capacity and type of message or signal is found in the electrical diagram If the floating relay contacts are connected to an external voltage source voltage may be present even when the machine is is...

Page 40: ...g the heat recovery system If necessary the operating element in the combination valve can be exchanged for one with higher opening temperature The opening temperature depends on operating and ambient...

Page 41: ...d STANDSTILL operating modes en sures load changes at minimum material stresses The controller SIGMA CONTROL BASIC can operate in the following modes DUAL QUADRO MODULATING control Energy efficient co...

Page 42: ...L Tab 39 Operating modes under MODULATING control 4 7 Refrigeration Dryer Control Modes The controller can operate in the following modes CONTINUOUS TIMER CONTINUOUS The refrigeration dryer will remai...

Page 43: ...be set Door interlock switches The machine will stop automatically if a safety interlocked door or panel is opened or removed Enclosures and guards for moving parts and electrical connections Protect...

Page 44: ...Lights green when the power supply is switched on 19 Machine ON Lights green when the machine switched on Tab 42 Indicators 4 10 Functional description SIGMA CONTROL BASIC 4 10 1 Display layout x x x...

Page 45: ...lue upon completion of the service activities The in terval starts anew A password is required to change this parameter 3 Relief valve test mode This function switches the activating pressure check mo...

Page 46: ...hing point The switching point corresponds to the working pressure of the air system and the cut out pressure of the machine Setting range bar 5 5 maximum operating overpressure E maximum possible set...

Page 47: ...g such that the display can be read and work carried out comfortably and safely Keep suitable fire extinguishing agents ready for use Ensure that required ambient conditions are maintained Required am...

Page 48: ...he enclosure remain opened 5 If installed outdoors the machine must be protected from frost direct sunlight dust and rain 5 2 2 Ensuring the machine room ventilation Adequate ventilation of the machin...

Page 49: ...Flaps or shutters that are opened by the the action of airflow against the force of gravity do not open sufficiently at low cooling fan speeds Further information Further information on installation...

Page 50: ...ontrolled release of this energy can cause serious injury or death The following safety concerns relate to any work on components that could be under pressure Close shut off valves or otherwise isolat...

Page 51: ...ipework 1 Flexible pressure hose 2 Shut off valve Do not induce any forces into the machine for which the compressive forces must be bal anced by bracing 1 WARNING Serious injury or death can result f...

Page 52: ...off and lock out the power supply disconnecting device and verify the absence of voltage 8 Connect the machine to the power supply 9 Ensure that the cabinet again complies with the requirements of de...

Page 53: ...aximum length 100 m recommended NYSLY 2x1 0 mm2 Fig 12 Connections SIGMA CONTROL BASIC 1 Input I4 Pin 7 2 Supply 24 VDC Pin 9 1 Lay the cable in a manner that it is not stressed when the control cabin...

Page 54: ...3 3 6 7 2 Option W1 Connecting the external heat recovery system An unsuitable heat exchanger or incorrect installation may influence the cooling oil circuit within the compressor Damage to the machin...

Page 55: ...energy Uncontrolled release of this energy can cause serious injury or death The following safety concerns relate to any work on components that could be under pressure Close shut off valves or other...

Page 56: ...hine To be checked See chapter Confirmed Are the operators fully conversant with safety regulations Have all the positioning conditions been fulfilled 5 Is a user s lockable power supply disconnecting...

Page 57: ...higher than the arithmetical phase cur rent Check the overload protection cut out setting The overload protection cut out shuts the machine down despite being correctly set Contact KAESER Service 7 5...

Page 58: ...ivate and deactivate the MODULATING control If the MODULATING control is deactivated the machine always delivers the maximum possible compressed air quantity in LOAD mode MODULATING control Shut off v...

Page 59: ...or Interlock Switch The interlock switch stops the machine as soon as the front access panel is opened Check the interlock switch function before every start up The door interlock switch is an importa...

Page 60: ...hine stop when the compressor motor rotates in the wrong direction Switch off and lock out the power supply isolating device and verify the absence of volt age Changeover phase lines L1 and L2 7 9 Set...

Page 61: ...rrow keys until the parameter C setpoint pressure switching differential is dis played in line 3 2 Press and hold enter for at least 3 seconds until the cursor flashes 3 Use the arrow keys to set the...

Page 62: ...After the controller has carried out a self test the green Power ON LED lights continuously 2 Press the ON key The green Machine ON LED lights continuously If a power failure occurs the machine is not...

Page 63: ...ching off in an emergency and switching on again The EMERGENCY STOP push button is located below the control panel Fig 17 Switching off in an emergency 9 EMERGENCY STOP control device Switching off Pr...

Page 64: ...of the required password flashes Changing a parameter that is not password protected Precondition The current parameter setting flashes Use the UP DOWN keys to change the value of the parameter and co...

Page 65: ...shes Message gone LED flashes Message reset LED extinguished Rectify the fault and acknowledge the message with the acknowledge key alarm LED extinguishes The machine is now ready to start again Warni...

Page 66: ...access door open or panel if present removed Unlatch the EMERGENCY STOP push button Close the access door or fit the panel 2 Motor alarm Overload protection of drive or fan motor if fitted On machine...

Page 67: ...ng exceeded Ensure adequate ventilation Ensure that the permissible room temperature is not exceeded 8 Reserve Tab 49 Alarm indications 9 3 Warning messages The fault code appears in the 4th line of t...

Page 68: ...IDLE more than twice per minute Air receiver too small Increase size of air receiver Airflow into the compressed air network restricted Increase air pipe diameters Check filter elements The differenti...

Page 69: ...controlled release of this energy can cause serious injury or death The following safety concerns relate to any work on components that could be under pressure Close shut off valves or otherwise isola...

Page 70: ...task The counting down of the maintenance interval indicator shows when the next maintenance action is due Reset the counter to the original value once the task has been carried out 1 Select paramete...

Page 71: ...s 10 5 Maintain the heat recovery system 10 6 Check that all electrical connections are tight Have the refrigerant circuit checked and documented by an authorised KAESER Service Technician Have the sa...

Page 72: ...an authorised KAESER Service Technician should carry out service work Have service tasks carried out punctually taking ambient and operating conditions into ac count Interval Service task Up to 12 000...

Page 73: ...Clean or renew the filter mat A filter mat is placed behind every ventilation grille Filter mats protect the control cabinet from in gress of dirt If the filter mats are clogged adequate cooling of t...

Page 74: ...mpressed air The frequency is mainly dependent on local operating conditions A leaking cooler results in loss of cooling oil and compressed air Clogged coolers are indicative of unfavourable ambient c...

Page 75: ...ve severe clogging removed by an authorised KAESER Service Technician Checking the cooler for leaks Visual inspection Did cooling oil escape Is a cooler leaking Have the defective cooler repaired imme...

Page 76: ...e that no voltage is present The machine has cooled down Fig 22 Air filter maintenance 1 Snap fastener 2 Air filter element 3 Air filter housing 1 Release the spring clips and remove the element 2 Cle...

Page 77: ...ut 3 Marker pin the illustration shows that belt tensioning is required Checking the belt tension and adjustment The tensioning device uses spring force to apply correct tension to the belts Adjust th...

Page 78: ...sted only by KAESER Service The machine must be isolated from the compressed air network and completely vented be fore undertaking any work on the pressure system Preparation for the test Precondition...

Page 79: ...Open the user s shut off valve between the machine and the air distribution network 10 11 Checking the Excess Temperature Safety Shutdown Function The machine should shut down if the airend discharge...

Page 80: ...rom the compressed air network and completely vented be fore undertaking any work on the pressure system Material The maintenance hose with hose coupling and shut off valve needed for venting is stowe...

Page 81: ...complete air system is vented With the shut off valve closed insert the male hose fitting 6 into the hose coupling 3 Slowly open the shut off valve 7 to release pressure Disconnect the male hose fitti...

Page 82: ...separator tank venting 4 Oil filler port with plug 5 Cooling oil level indicator 6 Plug in nozzle 7 Shut off valve A Shut off valve open B Shut off valve closed 8 Maintenance hose 1 Vent the machine...

Page 83: ...r the section from the shut off valve to the minimum pres sure check valve 1 With the shut off valve closed insert the male hose fitting 6 into the hose coupling 1 2 Slowly open the shut off valve 7 t...

Page 84: ...r from the compres sor itself or from an external source An external source of compressed air is necessary in the following cases The machine is not operational The machine is to be restarted after a...

Page 85: ...t at least 2 minutes to allow the oil to flow back to the separator tank The supply disconnecting device is switched off the device is locked off the absence of voltage has been verified The machine i...

Page 86: ...oil from the thermostatic valve If the machine is connected to an external heat recovery system oil should also be drained from the heat exchanger at a suitable point Precondition The external heat re...

Page 87: ...e must be isolated from the compressed air network and completely vented be fore undertaking any work on the pressure system Material Spares Cooling oil receptacle Precondition The power supply isolat...

Page 88: ...and reset the maintenance interval counter 4 After approx 10 minutes of operation Check the cooling oil level and top up if necessary 5 Switch off the machine and check visually for leaks 10 17 Changi...

Page 89: ...ke out the old oil separator cartridge 23 together with the gaskets 21 and dispose of ac cording to environmental protection regulations 6 Clean all sealing faces 7 Insert the new oil separator cartri...

Page 90: ...nd clean the refrigerant condenser and condensate drain regularly as described below 10 18 1 Cleaning the refrigerant condenser Precondition The supply disconnecting device is switched off the device...

Page 91: ...eel a short burst at the condensate drain hose Service the condensate drain if you do not experience a burst 10 18 3 Condensate drain maintenance The condensate drain cannot be cleaned The service uni...

Page 92: ...ndition Use only genuine KAESER service modules Make sure the top of the service module and the contact spring are clean and dry 1 Screw the service module to the inlet pipe using sealing tape 2 Caref...

Page 93: ...nance 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...

Page 94: ...or operating fluids materials Use only original KAESER parts and operating fluids materials Have an authorised KAESER Service Technician carry out regular maintenance Machine Name Quantity Number Air...

Page 95: ...air Use this parts list to plan your material requirement according to operating conditions and to order the required spare parts Make sure that any service or repair tasks not described in this manua...

Page 96: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 86 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 97: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 9_5717 20 E Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 87...

Page 98: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 88 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 99: ...11 Spares Operating Materials Service 11 5 Spare Parts for Service and Repair 9_5717 20 E Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 89...

Page 100: ...Allow the machine to cool down completely 2 Disconnect all air and electrical connections 12 2 Packing A wooden crate is required for overland transport to protect the machine from mechanical damage O...

Page 101: ...e in freezing tempera tures Precondition Transport only using a forklift truck or lifting gear and only by personnel trained in the safe trans portation of loads Make sure the danger area is clear of...

Page 102: ...t the machine carefully 12 5 Disposal When disposing of a machine drain out all liquids and remove dirty filters Precondition The machine is decommissioned 1 Completely drain the cooling oil from the...

Page 103: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_5717 20 E Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 93...

Page 104: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 94 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 105: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_5717 20 E Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 95...

Page 106: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 96 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 107: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 9_5717 20 E Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 97...

Page 108: ...13 Annex 13 1 Pipeline and instrument flow diagram P I diagram 98 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 109: ...line and instrument flow diagram P I diagram MODULATING control 13 Annex 13 2 Pipeline and instrument flow diagram P I diagram MODULATING control 9_5717 20 E Service Manual Screw Compressor ASK T SIGM...

Page 110: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram MODULATING control 100 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 111: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram MODULATING control 9_5717 20 E Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 101...

Page 112: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram MODULATING control 102 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 113: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram MODULATING control 9_5717 20 E Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 103...

Page 114: ...13 Annex 13 2 Pipeline and instrument flow diagram P I diagram MODULATING control 104 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 115: ...13 3 Dimensional drawing 13 Annex 13 3 Dimensional drawing 9_5717 20 E Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 105...

Page 116: ...13 Annex 13 3 Dimensional drawing 106 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

Page 117: ...inal noch Vervielf ltigungen d rfen Dritten ausgeh ndigt oder in sonstiger Weise zug nglich gemacht werden Entwicklungsbedingte nderungen vorbehalten Zeichnung darf nur ber CAD ge ndert werden A3 1020...

Page 118: ...13 4 Electrical Diagram 13 Annex 13 4 Electrical Diagram 108 Service Manual Screw Compressor ASK T SIGMA CONTROL BASIC 9_5717 20 E...

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