Page 1 Operating Manual Screw Compressor 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...
Page 2 Original instructions /KKW/SASK 2.22 en SBA-SCHRAUBEN-SC2IO /KKW/SSC 2.08 20170919 084918...
Page 3: Table Of Contents
Contents Regarding this document Using this document ......................Further documents ......................Copyright .......................... Symbols and labels ......................1.4.1 Warnings ......................1.4.2 Potential damage warnings ................1.4.3 Other alerts and their symbols ................Technical Specifications Nameplate ........................Options ..........................Mass ..........................Temperature ........................
Page 4 Contents 4.2.2 Floating relay contacts ..................Operating panel SIGMA CONTROL 2 ................Operating modes and control modes ................4.4.1 Machine operating modes .................. 4.4.2 Control modes ....................Options ..........................4.5.1 SIGMA CONTROL 2 controller: Connection to control technology ....4.5.2 Machine mountings .....................
Page 5 10.19 Documenting maintenance and service work ..............Spares, Operating Materials, Service 11.1 Note the nameplate ......................11.2 Ordering consumable parts and operating fluids/materials ..........11.3 KAESER AIR SERVICE ....................11.4 Replacement parts for service and repair ................ Decommissioning, Storage and Transport 12.1 De-commissioning ......................
Page 6 Contents Operating Manual Screw Compressor 901824 12 E...
Page 7 List of Illustrations Fig. 1 Maximum relative humidity of intake air ..................Fig. 2 Location of safety signs ......................Fig. 3 Housing overview ........................Fig. 4 Machine layout ........................... Fig. 5 Keys – overview ......................... Fig. 6 Indicators – overview ........................Fig.
Page 8 List of Illustrations Operating Manual Screw Compressor 901824 12 E...
Page 9 List of Tables Tab. 1 Danger levels and their definition (personal injury) ..............Tab. 2 Danger levels and their definition (damage to property) ............Tab. 3 Nameplate ..........................Tab. 4 Options ............................Tab. 5 Mass ............................Tab. 6 Temperature ..........................Tab.
Page 10 List of Tables Tab. 55 Other faults and remedies ......................Tab. 56 Advise others that the machine is being serviced..............Tab. 57 Regular maintenance tasks ......................Tab. 58 Cooling oil Change intervals ....................... Tab. 59 Regular service tasks ......................... Tab.
Page 11: Regarding This Document Using This Document
➤ Make sure you provide the data from the nameplate when ordering documents. Copyright This operating manual is protected by copyright. Any queries regarding the use or duplication of this documentation should be referred to KAESER. Correct use of information will be fully suppor‐ ted. Symbols and labels ➤...
Page 12: Potential Damage Warnings
Regarding this document Symbols and labels Example: DANGER These show the kind of danger and its source. The possible consequences of ignoring a warning are shown here. If you ignore the warning notice, the "DANGER" signal word indicates a lethal or severe in‐ jury will occur.
Page 13 Regarding this document Symbols and labels Material Here you will find details on special tools, operating materials or spare parts. Precondition Here you will find conditional requirements necessary to carry out the task. Here conditions relevant to safety are named that will help you to avoid dangerous situations. Option H1 ➤...
Page 14: Technical Specifications Nameplate
Technical Specifications Nameplate 2 Technical Specifications Nameplate The model designation and important technical information are given on the machine's nameplate. The nameplate is located on the outside of the machine: ■ above the cooler, or ■ on the rear of the machine. ➤...
Page 15: Mass
Technical Specifications Mass Mass The values shown are maximum values. Actual mass of individual machines are dependent on equipment fitted. ASK 28 ASK 34 ASK 40 Mass [kg] Tab. 5 Mass Temperature ASK 28 ASK 34 ASK 40 Minimum cut-in tempera‐...
Page 16: Ventilation
Maximum relative humidity of intake air Intake air temperature [°C] Maximum relative humidity of intake air [%] Ventilation The values given are minimum guide values. Mains frequency: 50 Hz ASK 28 ASK 34 ASK 40 Inlet aperture see fig‐ ure 10 [m...
Page 17: Flow Rate (Constant Delivery Volume Relative To Intake Conditions)
Technical Specifications Flow rate (constant delivery volume relative to intake conditions) Pressure relief valve activating pressure at 50 Hz [bar]: Maximum working over‐ ASK 28 ASK 34 ASK 40 pressure [bar] 11.0 15.0 * China: 15.9 Tab. 10 Pressure relief valve activating pressure (50Hz) Pressure relief valve activating pressure at 60 Hz [bar]: Maximum working over‐...
Page 18: Cooling Oil Recommendation
Technical Specifications Cooling oil recommendation Cooling oil recommendation A sticker showing the type of oil used is located near the oil separator tank filler. Information on ordering cooling oil is found in chapter 11. Cooling oils for general applications SIGMA FLUID S-460 S-570 Description...
Page 19: Cooling Oil Charge Quantity
Technical Specifications 2.10 Cooling oil charge quantity SIGMA FLUID FG-460 FG-680 Approval USDA H-1, NSF USDA H-1, NSF Approved for the manufacture of Approved for the manufacture of food food packaging, meat and poultry packaging, meat and poultry processing processing and other food process‐ and other food processing applications.
Page 20: Motors And Power
Technical Specifications 2.11 Motors and power ASK 28 ASK 34 ASK 40 Fluid volume* [l] Topping up volume [l] (minimum–maximum) * plus the cooling oil volume of the heat recovery system. Tab. 17 Cooling oil charge quantity Option W2/W3 Heat recovery...
Page 21: Fan Motor
Technical Specifications 2.12 Noise emission [dB(A)] Max. working pres‐ ASK 28 ASK 34 ASK 40 sure [bar] 11.0 3565 3565 3565 15.0 3565 3565 3565 Tab. 22 Compressor drive motor: Rated speed for 60 Hz 2.11.2 Fan motor Mains frequency: 50 Hz...
Page 22: Power Supply Specifications
Cable length >50 m Further information The wiring diagram in chapter 13.4 contains further details of the electrical connection data. 2.14.1 Mains frequency: 50 Hz Rated voltage: 200V / 3 / 50Hz ASK 28 ASK 34 ASK 40 Backup fuse [A] 4x25 4x35...
Page 23: Mains Frequency: 60 Hz
Technical Specifications 2.14 Power supply specifications Rated voltage: 230V / 3 / 50Hz ASK 28 ASK 34 ASK 40 Backup fuse [A] 4x16 4x25 4x35 Supply cable [mm Current drawn [A] Tab. 27 Supply details 230V / 3 / 50Hz...
Page 24: Heat Recovery
Technical Specifications 2.15 Heat recovery ASK 28 ASK 34 ASK 40 4x16 4x25 4x35 Supply cable [mm Current drawn [A] Tab. 30 Supply details 230V / 3 / 60Hz Rated voltage: 380V / 3 / 60Hz ASK 28 ASK 34...
Page 25: Tab. 34 Heat Recovery: Individual Design Data
➤ If required, enter your individual values in the prepared table. ➤ Consult KAESER SERVICE if you wish to use a different heat-receiving medium. The primary side of the heat exchanger is connected to the cooling oil circuit of the machine.
Page 26: Tab. 36 Quality Of The Heat Receiving Medium
Bacterial count [CFU*/ml] 10,000 Suspended solids [ppm] <20 (portion of undissolved matter) * CFU: colony-forming units Tab. 36 Quality of the heat receiving medium Heat capacity Maximum heat capacity ASK 28 ASK 34 ASK 40 available [kW] 13.6 16.9 19.8 [MJ/h] [kcal/h]...
Page 27: Tab. 39 Flow Rate / Pressure Drop (Option W3)
Technical Specifications 2.15 Heat recovery ASK 28 ASK 34 ASK 40 Pressure drop [bar] 0.10 0.10 0.10 Tab. 39 Flow rate / pressure drop (option W3) Operating Manual Screw Compressor 901824 12 E...
Page 28: Safety And Responsibility Basic Instructions
Safety and Responsibility Basic instructions 3 Safety and Responsibility Basic instructions The machine is manufactured to the latest engineering standards and acknowledged safety regula‐ tions. Nevertheless, dangers can arise through its operation: ■ danger to life and limb of the operator or third parties, ■...
Page 29: Determining Personnel
Safety and Responsibility User's responsibilities ➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐ nance of the machine. 3.4.2 Determining personnel Suitable personnel are experts who, by virtue of their training, knowledge and experience as well as their knowledge of relevant regulations can assess the work to be done and recognize the pos‐ sible dangers involved.
Page 30: Dangers
Inspection Inspection interval Inspecting authority Installation and equip‐ Before commissioning Competent person ment inspection (e. g. KAESER SERVICE technician) Internal inspection Every 5 years after installation or Competent person the last inspection (e. g. KAESER SERVICE technician) Strength test Every 10 years after installation or...
Page 31 Safety and Responsibility Dangers ➤ De-pressurise all pressurised components and enclosures. ➤ Do not carry out welding, heat treatment or mechanical modifications on pressurised compo‐ nents (e.g. pipes and vessels) as this influences the component's resistance to pressure. The safety of the machine is then no longer ensured. Compressed air quality The composition of the compressed air must be suitable for the actual application in order to pre‐...
Page 32: Safe Machine Operation
Unsuitable spare parts compromise the safety of the machine. ➤ Use only spare parts approved by the manufacturer for use in this machine. ➤ Use only genuine KAESER replacement parts on pressure bearing parts. Conversion or modification of the machine Modifications, additions to and conversions of the machine or the controller can result in unpredict‐...
Page 33 Safety and Responsibility Dangers ■ Safety boots ■ Eye protection ■ Ear protection Transport The mass and size of the machine require safety measures during its transport to prevent acci‐ dents. ➤ Use suitable lifting gear that conforms to local safety regulations. ➤...
Page 34: Organisational Measures
➤ Do not open the cabinet while the machine is switched on. ➤ Do not open or dismantle any valves. ➤ Use only spare parts approved by KAESER for use in this machine. ➤ Carry out regular inspections: for visible damages,...
Page 35: Safety Devices
EMERGENCY STOP control device ■ Mains contactor 1. The components of the safety functions must be replaced by KAESER SERVICE after a work‐ ing life of 20 years. 2. Have the KAESER SERVICE check the reliability of the safety functions.
Page 36: Safety Signs
Safety and Responsibility Safety signs Safety signs The illustration shows the position of the safety signs on the machine. The table lists the various safety signs used and their meanings. Fig. 2 Location of safety signs Item Sign Meaning Danger of fatal injury from electric shock! ➤...
Page 37: Emergency Situations
Safety and Responsibility Emergency situations Item Sign Meaning Risk of fatal injury when dismantling valves (spring-loaded or under pressure)! ➤ Do not open or dismantle valves. ➤ Call an authorised Service Technician in the event of a fault. Serious injury, particularly to the eyes, from foreign objects ejected from rotating components.
Page 38: Warranty
■ incorrect maintenance, ■ incorrect repair. Correct maintenance and repair includes the use of genuine KAESER spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. 3.11 Environment protection The operation of this machine may cause dangers for the environment.
Page 39: Design And Function
Design and Function Housing 4 Design and Function Housing Fig. 3 Housing overview Control cabinet door Sight glass: Cooling oil level indicator Latch Sight glass: V-belt tension Access door When closed, the enclosure serves various functions: ■ Sound insulation ■ Protection against contact with components ■...
Page 40: Machine Function
Design and Function Machine function Machine function Fig. 4 Machine layout Inlet valve Control cabinet Minimum pressure/check valve Oil separator tank Compressor motor Air filter Oil filter Oil/air cooler Airend Ambient air is cleaned as it is drawn in through the filter The air is then compressed in the airend The airend is driven by an electric motor Cooling oil is injected into the airend.
Page 41: Floating Relay Contacts
Design and Function Operating panel SIGMA CONTROL 2 ■ Pressure relief valve: The pressure relief valve protects the system against excessive pressure. It is factory set. ■ Resistance thermometer: Monitoring the airend discharge temperature protects the compressed air system from imper‐ missible temperature rises.
Page 42: Fig. 6 Indicators - Overview
Design and Function Operating panel SIGMA CONTROL 2 Position Name Function «Down» Scrolls down the menu options. Reduces a parameter value. «Right» Jumps to the right. Moves the cursor position to the next right field. «Left» Jumps to the left. Moves the cursor position to the next left field.
Page 43: Fig. 7 Rfid Reader
Placing a suitable transponder in front of the RFID reader of the controller will automatically acti‐ vate the communication between transponder and SIGMA CONTROL 2. A suitable transponder is the KAESER RFID Equipment Card. Two of them have been provided with the machine.
Page 44: Operating Modes And Control Modes
Design and Function Operating modes and control modes Operating modes and control modes 4.4.1 Machine operating modes STOP The machine is connected to the power supply. voltage applied to controller LED lights green. The machine is switched off. The on LED is extinguished. READY The machine has been activated with «ON»: on LED lights green.
Page 45: Tab. 47 Energy-Saving Control Modes
Design and Function Operating modes and control modes The following control modes can be set: ■ DUAL ■ QUADRO ■ VARIO Supplementary mechanical flow rate regulation: Option C1 ■ MODULATING control Energy-efficient control modes for various applications: Application Recommended control mode Compressed air station with one machine or several machines supplying VARIO similar volumes.
Page 46: Options
Design and Function Options Options The options available for your machine are described below. 4.5.1 Option C3/C48 SIGMA CONTROL 2 controller: Connection to control technology Connection to various control technology systems is possible with the C3 option. Option C3 Option C48 Main Control System (MCS): Main Control System Input Output (MCSIO): ■...
Page 47: Fig. 9 Function Of The Heat Recovery
Design and Function Options Both oil temperature regulators are equipped with working elements that ensure trouble-free func‐ tioning of the cooling and heat recovery systems. Fig. 9 Function of the heat recovery Plate-type heat exchanger Operating Manual Screw Compressor 901824 12 E...
Page 48: Installation And Operating Conditions
The clearances given are recommended and ensure unhindered access to all machine parts. ➤ Please consult KAESER if they cannot be adhered to. Precondition The floor must be level, firm and capable of bearing the mass of the machine.
Page 49: Ensuring The Machine Room Ventilation
It evacuates the exhaust heat of the machine and thus ensures the required operating condi‐ tions. ➤ Consult with KAESER if you cannot ensure the conditions for an adequate ventilation of the machine room. 1. Ensure that the flow volume of fresh air is at least the same as the volume taken by the ma‐...
Page 50: Exhaust Duct Design
At the cooling air inlet and exhaust, the machine can only overcome the air resistance resulting from the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐ ing. ➤ Consult the KAESER SERVICE representative before deciding on: ■ Design of the exhaust air ducting ■...
Page 51: Installation
Installation Ensuring safety 6 Installation Ensuring safety Follow the instructions below for safe installation. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Page 52: Reporting Transport Damage
➤ Install only corrosion-resistant pipes. ➤ Use fluoroelastomers as sealing material for seals. ➤ Note the electro-chemical voltage sequence. ➤ Consult with KAESER for suitable materials for the compressed air network. Precondition The compressed air system is vented completely to atmospheric pressure.
Page 53: Connecting The Machine With The Power Supply
Safety monitoring of the machine's internal pressure is unaffected. Your authorized KAESER SERVICE technician will be glad to provide support on planning and executing an individual solution. 1. Install the pressure transducer at the selected location in the compressed air network.
Page 54: Options
Installation Options Options 6.6.1 Option H1 Anchoring the machine ➤ Use appropriate fixing bolts to anchor the machine. Further information Details of the fixing holes are contained in the dimensional drawing in chapter 13.3. 6.6.2 Option W2/W3 Connecting the heat recovery system ➤...
Page 55 Installation Options 4. Slowly open the shut-off valve at the inlet to gradually fill the heat exchanger with the heat transfer medium. 5. Bleed the lines. Further information The dimensional drawing in chapter 13.3 gives the flow direction, size and position of the connec‐ tion ports.
Page 56: Initial Start-Up Ensuring Safety
Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Here you will find instructions for a safe commissioning of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Page 57: Instructions To Be Observed Before Commissioning
➤ Change the oil filter. ➤ Change the oil separator cartridge. ➤ Change the cooling oil. ➤ Have the motor bearings checked by an authorized KAESER SERVICE technician. 36 months ➤ Have the overall technical condition checked by an authorised KAESER SERVICE technician.
Page 58: Setting The Overload Protection Cut-Out
➤ Check the settings of the overload relay. The overload relay shuts the machine down despite being correctly set? ➤ Contact the authorised KAESER SERVICE. Setting the motor overload protection switch Electrical diagram in chapter 13.4 gives the setting values for the motor overload protection switch.
Page 59: Activating And Deactivating The Modulating Control
Initial Start-up Activating and deactivating the MODULATING control Material 1 l cooling oil Precondition Cut-off the electrical power supply via the power supply isolating device, ensure that the device is locked off, verify the absence of any voltage. Fig. 13 Airend filling port Screw plug Screw plug...
Page 60: Starting The Machine For The First Time
Control valve (proportional control) Shut-off valve ➤ Open or close the shut-off valve, depending on the required control mode. The regulating valve is factory set. Consult with KAESER SERVICE before changing. Starting the machine for the first time Precondition No personnel are working on the machine.
Page 61: Setting The Set Point Pressure
Initial Start-up Setting the set point pressure Setting the set point pressure The system pressure pA is factory set to the highest possible value. Adjustment is necessary for individual operating conditions. Do not set the set point pressure of the machine higher than the maximum working pressure of the compressed air system.
Page 62: Operation
Operation Switching on and off 8 Operation Switching on and off Always switch the machine on with the «ON» key and off with the «OFF» key. A power supply disconnecting device has been installed by the user. Fig. 15 Switching on and off ON LED «LOAD/IDLE»...
Page 63: Switching Off In An Emergency And Switching On Again
Operation Switching off in an emergency and switching on again Voltage applied to controller LED extinguishes. The machine is switched off and disconnected Result from the mains supply. In rare cases, you may want to shut down the machine immediately and cannot wait until the automatic shut-down process is finished.
Page 64: Using The Timer For Switching On And Off
Operation Using the timer for switching on and off Fig. 17 Using the remote control for switching on and off «Remote control» key Remote control LED 1. Attach an easily seen notice to the machine that warns of remote operation. Remote control: Risk of injury caused by unexpected starting! ➤...
Page 65: Interpreting Operation Messages
Operation Interpreting operation messages Fig. 18 Using the timer for switching on and off «Timer» key Timer LED 1. Attach an easily seen notice warning of time-controlled operation: Time control: Risk of injury caused by unexpected starting! ➤ Make sure that the power supply disconnecting device is switched off before commencing any work on the machine.
Page 66: Fig. 19 Acknowledging Messages
Operation Acknowledging alarm and warning messages Fig. 19 Acknowledging messages Warning LED (yellow) Fault LED (red) «Acknowledge» key Alarm message Fault LED flashes red. An alarm shuts the machine down automatically. The The system displays the appropriate message. Precondition The fault has been rectified ➤...
Page 67: Fault Recognition And Rectification
1. Do not attempt fault rectification measures other than those given in this manual! 2. In all other cases: Have the fault rectified by an authorised KAESER SERVICE representative. Further information See the operating manual of SIGMA CONTROL 2 for details regarding the various messages.
Page 68: Tab. 55 Other Faults And Remedies
Oil cooler leaking. Call KAESER SERVICE. Leaking pipe joints. Tighten pipe joints. Replace seals. Cooling oil consumption too Unsuitable oil is being used. Change to SIGMA FLUID cool‐...
Page 69: 10.1 Maintenance
Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 Ensuring safety Follow the instructions below to ensure safe machine maintenance. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety notes Disregard of safety notes can cause unforeseeable dangers! ➤...
Page 70: Following The Maintenance Plan
Details of dangers and their avoidance are found in chapter 3.5. 10.2 Following the maintenance plan 10.2.1 Logging maintenance work The maintenance intervals given are those recommended for KAESER original components with average operating conditions. ➤ In adverse conditions, perform maintenance work at shorter intervals. Adverse conditions are, e.g.: ■...
Page 71: Cooling Oil Change Interval
Cooling oil Change interval Duty cycles and ambient conditions are important factors influencing the number and length of the oil change intervals. KAESER SERVICE will support you in determining appropriate intervals and provide informa‐ tion on the possibilities of oil analysis. Operating Manual...
Page 72: Regular Service Tasks
10.2.5 Regular service tasks The table below lists necessary service tasks. ➤ Have an authorised KAESER SERVICE technician carry out service tasks. ➤ Have service tasks carried out in a timely manner, taking the ambient and operating conditions into account:...
Page 73: Cooler: Cleaning Or Renewing The Filter Mats
Maintenance 10.3 Cooler: Cleaning or Renewing the Filter Mats 10.3 Cooler: Cleaning or Renewing the Filter Mats The filter mats help to keep the cooler clean. If the filter mats are clogged, adequate cooling of the components is no longer ensured. Material Filter mats: Warm water and household detergent...
Page 74: Cooler Maintenance
Clogged coolers are indicative of unfavourable ambient conditions. Such ambient conditions clog the cooling air ducts in the machine's interior and the motors resulting in increased wear and tear. ➤ Have the authorised KAESER SERVICE technician clean the cooling air ducts. Material Brush and vacuum cleaner...
Page 75: Maintain The Heat Recovery System
➤ Have stubborn clogging removed by an authorized KAESER SERVICE technician. Checking the cooler for leaks ➤ Carry out visual inspection: Did cooling oil escape? Is a cooler leaking? ➤ Have the defective cooler repaired immediately by a KAESER SERVICE technician. 10.6 Option W2/W3 Maintain the heat recovery system Deposits in the heat exchanger can significantly reduce its capacity to transfer heat.
Page 76: Air Filter Maintenance
Maintenance 10.7 Air Filter Maintenance 1. Check the heat exchanger visually for leaks. 2. Have KAESER SERVICE check the heat exchanger for internal leaks and clean if contamina‐ ted. 10.7 Air Filter Maintenance Check that all sealing surfaces match each other. The use of an unsuitable air filter element can permit dirt to ingress the pressure system and cause damage to the machine.
Page 77: Drive Belt Maintenance
Maintenance 10.9 Drive belt maintenance 10.9 Drive belt maintenance Material Spare parts (if required) Precondition Cut-off the electrical power supply via the power supply isolating device, ensure that the device is locked off, verify the absence of any voltage. The machine has cooled down. WARNING Touching the moving drive belt may result in severe bruising or even loss of limb or extremi‐...
Page 78: Testing The Pressure Relief Valve
Maintenance 10.10 Testing the pressure relief valve 3. In case of damage: Replace the drive belt immediately. 4. Replace the belt guard and tighten the screw plugs. Replace the drive belt. 1. Loosen the screw plugs and lift the belt guard 2.
Page 79: Check The Safety Shut-Down Due To Excessive Airend Discharge Temperature
➤ Check the safety shutdown function as described in the SIGMA CONTROL 2 operating man‐ ual. The machine does not shut down? ➤ Have the safety shut-down function checked by an authorised KAESER SERVICE tech‐ nician. 10.12 Check the EMERGENCY STOP control device Fig.
Page 80: Venting The Machine (De-Pressurising)
Maintenance 10.14 Venting the machine (de-pressurising) Fig. 26 Checking the cooling oil level Oil level minimum Oil level maximum Oil level optimum 1. CAUTION! Danger of burning - hot surfaces! ➤ Wear long-sleeved clothing and protective gloves. 2. Check the cooling oil level with machine running under LOAD. Result As soon as the minimum level is reached: Top up the cooling oil.
Page 81: Fig. 27 Venting The Machine
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact the authorised KAESER SERVICE. Manually venting the air cooler After shutting down the compressor and venting the oil separator tank, the machine is still un‐...
Page 82: Replenish Cooling Oil
Maintenance 10.15 Replenish cooling oil 10.15 Replenish cooling oil The machine must be isolated from the compressed air network and completely vented be‐ fore undertaking any work on the pressure system. Material The hose coupling, shut-off valve and maintenance hose required for venting lie beneath the oil separator tank.
Page 83: Topping Up With Cooling Oil And Trial Run
➤ If manual venting does not bring the oil separator tank pressure gauge to zero: Contact the authorised KAESER SERVICE. Manually venting the air cooler After shutting down the compressor and venting the oil separator tank, the machine is still un‐...
Page 84: Changing The Cooling Oil
Maintenance 10.16 Changing the cooling oil Starting the machine and performing a trial run 1. Close all access doors, replace and secure all removable panels. 2. Open the user's shut-off valve between the machine and the air distribution network. 3. After approx. 10 minutes of operation: Check the cooling oil level and top up if necessary. 4.
Page 85: Fig. 29 Changing The Cooling Oil, Pressuring The Oil Separator Tank
Draining the oil from the separator tank Contact KAESER SERVICE if condensate is detected in the cooling oil. It is necessary to adapt the airend discharge temperature to individual ambient conditions. Operating Manual...
Page 86: Fig. 30 Changing The Cooling Oil Oil Separator Tank
Maintenance 10.16 Changing the cooling oil Fig. 30 Changing the cooling oil Oil separator tank Plug-in nozzle Hose coupling (oil drainage) Shut-off valve Shut-off valve (oil drainage) Maintenance hose 1. Prepare a cooling oil receptacle. 2. With the shut-off valve closed, insert the plug-in nozzle into the hose coupling 3.
Page 87: Fig. 32 Changing The Cooling Oil Compressor Block
Maintenance 10.16 Changing the cooling oil 5. Slowly open the shut-off valve and allow cooling oil and air to escape completely until the pressure gauge reads 0 bar. 6. Close the shut-off valve and unplug the male hose fitting. ➤ Dispose of used oil in accordance with environment protection regulations. Draining the oil from the airend Fig.
Page 88: Fig. 33 Changing The Cooling Oil Heat Recovery
Maintenance 10.16 Changing the cooling oil Option W2/W3 Draining the oil from the heat exchanger Fig. 33 Changing the cooling oil Heat recovery Hose coupling Shut-off valve Shut-off valve Maintenance hose Plug-in nozzle 1. Prepare a cooling oil receptacle. 2. Insert the male hose fitting in the hose coupling 3.
Page 89: Changing The Oil Filter
Maintenance 10.17 Changing the oil filter 4. Fill with cooling oil. 5. Check the filler plug and ring seal for damage and screw the plug back in again. Starting the machine and performing a trial run 1. Close all access doors, replace and secure all removable panels. 2.
Page 90: Changing The Oil Separator Cartridge
Maintenance 10.18 Changing the oil separator cartridge Changing the oil filter 1. WARNING! Compressed air! Compressed air and devices under pressure can injure or cause death if the contained energy is released suddenly. ➤ De-pressurise all pressurised components and enclosures. 2.
Page 91: Fig. 36 Changing The Oil Separator Cartridge
Maintenance 10.18 Changing the oil separator cartridge Fig. 36 Changing the oil separator cartridge Cover Screw connection Dirt trap seal Air pipe Oil separator cartridge Retaining screw Ball (functioning as a check valve) Self-locking nut Strainer Changing the oil separator cartridge 1.
Page 92 Maintenance 10.18 Changing the oil separator cartridge Start the machine and carry out a trial run 1. Close all access doors, replace and secure all removable panels. 2. Open the user's shut-off valve between the machine and the air distribution network. 3.
Page 93: Documenting Maintenance And Service Work
Maintenance 10.19 Documenting maintenance and service work 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. 60 Logged maintenance tasks Operating Manual Screw Compressor 901824 12 E...
Page 94: 11 Spares, Operating Materials, Service
➤ Please give the information from the nameplate with every enquiry and order for spares. 11.2 Ordering consumable parts and operating fluids/materials KAESER consumable parts and operating materials are original components. They are specifically selected for use in KAESER machines. Unsuitable or poor quality consumable parts and operating fluids/materials may result in damage to the machine or impair its proper function.
Page 95: Replacement Parts For Service And Repair
Spares, Operating Materials, Service 11.4 Replacement parts for service and repair ➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement. Your advantage: lower costs and higher compressed air availability. 11.4 Replacement parts for service and repair Use this spare parts list to plan your material requirement according to operating conditions and to order the required spare parts.
Page 96 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operating Manual Screw Compressor 901824 12 E...
Page 97 Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operating Manual Screw Compressor 901824 12 E...
Page 98: 12.1 Decommissioning, Storage And Transport
Decommissioning, Storage and Transport 12.1 De-commissioning 12 Decommissioning, Storage and Transport 12.1 De-commissioning De-commissioning is necessary, for example, under the following circumstances: ■ The machine is (temporarily) not needed. ■ The machine is to be moved to another location. ■ The machine is to be scrapped.
Page 99: Packing
Mass and centre of gravity determine the most suitable method of transportation. The centre of gravity is shown in the drawing in chapter 13.3. ➤ Please consult with KAESER if you intend to transport the machine in freezing tempera‐ tures.
Page 100: Transport With A Hoist
Attached components such as centrifugal separators, condensate drains or filters ■ Rain protection covers ➤ Consult KAESER if you require suitable load-carrying and attachment devices or have questions regarding the correct use. Precondition Load-carrying and attachment devices meet the local safety regulations.
Page 101: Fig. 38 Transporting With A Crane
Decommissioning, Storage and Transport 12.4 Transport Fig. 38 Transporting with a crane Load carrying devices Attachment resources Crossbeam 1. WARNING! Risk of accident caused by incorrect use of load-carrying and attachment devices! ➤ Comply with permissible load limits. ➤ Comply with specific safety information of used load-carrying and attachment devices. 2.
Page 102: Disposal
Decommissioning, Storage and Transport 12.5 Disposal 12.5 Disposal When disposing of a machine, drain out all liquids and remove old filters. Precondition The machine is decommissioned. 1. Completely drain the cooling oil from the machine. 2. Remove used filters and the oil separator cartridge. 3.
Page 103: 13 Annex
Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) 13 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Screw Compressor 901824 12 E...
Page 104 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Screw Compressor 901824 12 E...
Page 105 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Screw Compressor 901824 12 E...
Page 106 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Screw Compressor 901824 12 E...
Page 107 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Screw Compressor 901824 12 E...
Page 108 Annex 13.1 Pipeline and instrument flow diagram (P&I diagram) Operating Manual Screw Compressor 901824 12 E...
Page 109: Pipeline And Instrument Flow Diagram (P&I Diagram) Modulating Control
Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control 13.2 Option C1 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Screw Compressor 901824 12 E...
Page 110 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Screw Compressor 901824 12 E...
Page 111 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Screw Compressor 901824 12 E...
Page 112 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Screw Compressor 901824 12 E...
Page 113 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Screw Compressor 901824 12 E...
Page 114 Annex 13.2 Pipeline and instrument flow diagram (P&I diagram) MODULATING control Operating Manual Screw Compressor 901824 12 E...
Page 115: Dimensional Drawing
Annex 13.3 Dimensional drawing 13.3 Dimensional drawing Operating Manual Screw Compressor 901824 12 E...
Page 116 Annex 13.3 Dimensional drawing Operating Manual Screw Compressor 901824 12 E...
Page 117 Annex 13.3 Dimensional drawing Operating Manual Screw Compressor 901824 12 E...
Page 118: Electrical Diagram
Annex 13.4 Electrical Diagram 13.4 Electrical Diagram Operating Manual Screw Compressor 901824 12 E...
Page 119 Annex 13.4 Electrical Diagram Operating Manual Screw Compressor 901824 12 E...
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Page 121 Annex 13.4 Electrical Diagram Operating Manual Screw Compressor 901824 12 E...
Page 122 Annex 13.4 Electrical Diagram Operating Manual Screw Compressor 901824 12 E...
Page 123 Annex 13.4 Electrical Diagram Equipment parts list ASK 28 model machine power supply 200 V ±10 %, 50 Hz 200 V ±10 %, 50 Hz 230 V ±10 %, 50 Hz 230 V ±10 %, 50 Hz 380 V ±10 %, 60 Hz 380 V ±10 %, 60 Hz 400 V ±10 %, 50 Hz 400 V ±10 %, 50 Hz 440 V ±10 %, 60 Hz 440 V ±10 %, 60 Hz...
Page 124 Annex 13.4 Electrical Diagram Equipment parts list ASK 34 model machine power supply 200 V ±10 %, 50 Hz 200 V ±10 %, 50 Hz 230 V ±10 %, 50 Hz 230 V ±10 %, 50 Hz 380 V ±10 %, 60 Hz 380 V ±10 %, 60 Hz 400 V ±10 %, 50 Hz 400 V ±10 %, 50 Hz 440 V ±10 %, 60 Hz 440 V ±10 %, 60 Hz 200 V ±10 %, 60 Hz 200 V ±10 %, 60 Hz...
Page 125 Annex 13.4 Electrical Diagram Equipment parts list ASK 40 model machine power supply 200 V ±10 %, 50 Hz 200 V ±10 %, 50 Hz 230 V ±10 %, 50 Hz 230 V ±10 %, 50 Hz 380 V ±10 %, 60 Hz 380 V ±10 %, 60 Hz 400 V ±10 %, 50 Hz 400 V ±10 %, 50 Hz 440 V ±10 %, 60 Hz 440 V ±10 %, 60 Hz 200 V ±10 %, 60 Hz 200 V ±10 %, 60 Hz...
Page 126 Annex 13.4 Electrical Diagram Operating Manual Screw Compressor 901824 12 E...
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Page 137 Annex 13.4 Electrical Diagram 230V~ 24V= -T21 -T11 24V= 230V~ -F11 230V~ -B25 The components are performance-related and not shown to scale. Operating Manual Screw Compressor 901824 12 E...
Page 138 Annex 13.4 Electrical Diagram Operating Manual Screw Compressor 901824 12 E...

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Ask 34 Ask series Ask 40

KAESER ASK 28 Operating Manual

1 Regarding this Document Using this Document

2 Technical Specifications Nameplate

3 Safety and Responsibility Basic Instructions

4 Design and Function

5 Installation and Operating Conditions

6 Installation

7 Initial Start-Up Ensuring Safety

8 Operation

9 Fault Recognition and Rectification

10 1 Maintenance

11 Spares, Operating Materials, Service

12 1 Decommissioning, Storage and Transport

13 Annex

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