Page 1 Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 2 Original instructions /KKW/SASD 1.00 en 01 SBA-SCHRAUBEN-TRI-VOLTAGE-T-SC...
Page 3: Table Of Contents
Pressure ........................... Delivery ..........................Cooling Oil Recommendation ..................2.9.1 Basic Information ....................2.9.2 KAESER Lubricants .................... 2.10 Cooling Oil Volume ......................2.11 Motors and Power ......................2.11.1 Drive motor ......................2.11.2 Fan motor ......................2.12 Sound Pressure Level ...................... 2.13 Power Supply ........................
Page 4 Contents Functional Description of the Machine ................Refrigeration dryer ......................Floating relay contacts ..................... Options ..........................4.5.1 Machine mountings ..................... 4.5.2 Cooling air filter mat .................... 4.5.3 Heat Recovery ....................4.5.4 Optional Filter Monitoring Set ................Operating States and Control Modes ................4.6.1 Operating states of the machine .................
Page 5 Contents Alarm messages (machine shut-down) ................Warning messages (yellow LED lights) ................Other Faults ........................Maintenance 10.1 Safety ..........................10.2 Maintenance Schedule ..................... 10.2.1 Logging maintenance work ................. 10.2.2 Resetting maintenance interval counters ............10.2.3 Regular maintenance tasks ................10.2.4 Cooling oil changing interval ................10.2.5 Regular Service Work ..................
Page 6 Contents 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode ... 13.3 Dimensional Drawing ....................... 104 13.4 Electrical Diagram ......................107 Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 7 List of Illustrations Fig. 1 Maximum relative humidity ......................Fig. 2 Three-phase star (wye); 4 wire; grounded neutral ..............Fig. 3 Three-phase star (wye); 3 wire; grounded neutral ..............Fig. 4 Location of safety signs ......................Fig. 5 Enclosure ........................... Fig.
Page 8 List of Illustrations Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 9 List of Tables Tab. 1 The levels of danger and their meaning ..................Tab. 2 Nameplate ..........................Tab. 3 Options ............................Tab. 4 Machine weight .......................... Tab. 5 Temperature ..........................Tab. 6 Ambient Conditions ........................Tab. 7 Ventilation ........................... Tab. 8 Safety relief valve setting ......................
Page 10 List of Tables Service Manual Screw Compressor viii ASD T Tri-Voltage 9_5721 06 USE...
Page 11: Regarding This Document Using The Document
➤ Make sure you give the data from the nameplate when ordering documents. Copyright This service manual is copyright protected. Queries regarding use or duplication of the documentation should be referred to KAESER. Correct use of information will be fully supported. Symbols and Identification 1.4.1 Warnings Warning notices indicate three levels of danger signified by the signal word.
Page 12: Other Instructions And Symbols
Regarding this Document Symbols and Identification Signal word Meaning Consequences of non-observance CAUTION Warns of a possibly dangerous situa‐ Light injuries or material damage are possible tion Tab. 1 The levels of danger and their meaning 1.4.2 Other instructions and symbols This symbol refers to particularly important information.
Page 13: Technical Data Nameplate
Technical Data Nameplate 2 Technical Data 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 ■ on the rear of the machine. ➤...
Page 14: Weight
Technical Data Weight Option Option code Exists? Heat recovery ΔT=55 K Tab. 3 Options Weight The weight given is the maximum. The actual weight of individual machine is dependent on equipment fitted. ASD 25 ASD 30 ASD 40S ASD 40 Weight [lb] 3640 4040...
Page 15: Ventilation
Technical Data Ventilation Fig. 1 Maximum relative humidity Inlet air temperature [°F] Maximum relative humidity of inlet air [%] Ventilation The values given are minimum guide values. ASD 25 ASD 30 ASD 40S ASD 40 Inlet aperture see fig‐ ure 13 [sq.ft.] Forced ventilation with ex‐...
Page 16: Delivery
Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic com‐ pressor cooling oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire- resistant fluid.
Page 17: Cooling Oil Volume
PAO and diester fluids. ■ S–460 lubricant is recommended for compressors operating in ambient temperatures between 40 °F and 105 °F. Specialty KAESER LUBRICANTS: ■ S–680 lubricant may be used when ambient temperatures are always between 70 °F and 105 °F. ■...
Page 18: Motors And Power
Technical Data 2.11 Motors and Power ASD 25 ASD 30 ASD 40S ASD 40 Additional charge volume [quart] Tab. 13 Cooling oil charge (option W3) 2.11 Motors and Power 2.11.1 Drive motor ASD 25 ASD 30 ASD 40S ASD 40 Rated power [hp] Enclosure protection TEFC...
Page 19: Power Supply
Three-phase star (wye); 4 wire; grounded neutral Fig. 3 Three-phase star (wye); 3 wire; grounded neutral Further information Please contact authorized KAESER Service representative for options. The electrical diagram 13.4 contains further specifications for electrical connection. 2.14 Power Supply specifications The following multi-strand copper core wires are given according to 2005 NEC 310.15, Table 310.16...
Page 20: Heat Recovery
Technical Data 2.15 Heat Recovery We strongly suggest using a separate copper conductor for the equipment GROUNDING. NEC Ta‐ ble 250.122 will point out the ”minimum size”, however, we recommend a ground conductor the same size as the power leads, if local codes allow. Rated power supply 208V ±10%, 3-ph, 60Hz ASD 25 ASD 30...
Page 21: Internal Heat Recovery
Generally water is used as the heat transfer medium. The water must meet the specification given below in order not to damage the heat exchanger. ➤ Consult authorized KAESER Service representative if you wish to use a different heat transfer medium.
Page 22: Refrigeration Dryer
Pressure drop [psi] <1.5 <1.5 <1.5 <1.5 Unsuitable heat transfer Seawater media Consult KAESER before using another type of heat transfer medium. Tab. 23 Heat exchanger specification (option W2/W3) Heat capacity Maximum heat capacity ASD 25 ASD 30 ASD 40S...
Page 23: Tab. 28 Refrigeration Dryer: Compressed Air System
Technical Data 2.16 Refrigeration dryer Compressed air system ABT 37 ABT 57 Pressure drop [psi] (in relation to 100 psig working pressure) Maximum permitted work‐ ing pressure [psig] Tab. 28 Refrigeration dryer: compressed air system Refrigerant circuit ABT 37 ABT 57 Refrigerant R134a R134a...
Page 24: Safety And Responsibility Basic Information
Safety and Responsibility Basic Information 3 Safety and Responsibility Basic Information 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 25: Qualified Personnel
Safety and Responsibility Dangers 3.4.2 Qualified personnel These are people who, by virtue of their training, knowledge and experience as well as their knowl‐ edge of relevant regulations can assess the work to be done and recognize the possible dangers involved.
Page 26: Safely Dealing With Sources Of Danger
Safety and Responsibility Dangers 3.5.1 Safely Dealing with Sources of Danger Information concerning the various forms of danger that can arise during machine operation are found here. Electricity ➤ Allow only qualified and authorized electricians or trained personnel under the supervision of a qualified and authorized electrician to carry out work on electrical equipment according to elec‐...
Page 27 ➤ Do not eat or drink while handling cooling and lubricating fluids. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Use only KAESER approved operating materials. Unsuitable spare parts ➤ Use only spare parts approved by the manufacturer for use in this machine.
Page 28: Safe Machine Operation
Safety and Responsibility Dangers 3.5.2 Safe Machine Operation Information on safe conduct when handling the machine is found here. Transport ➤ Use suitable lifting gear that conforms to local safety regulations. ➤ Allow transport only by personnel trained in the safe movement of goods. ➤...
Page 29: Safety Devices
Safety and Responsibility Safety Devices Activity Danger area Authorized personnel Transport Within a 10 ft radius of the machine. Installation personnel for transport preparation. No personnel during transport. Beneath the lifted machine. No personnel! Installation Within the machine. Installation personnel Within 3 ft radius of the machine and its supply cables.
Page 30: Fig. 4 Location Of Safety Signs
Safety and Responsibility Safety Signs Fig. 4 Location of safety signs Item Symbol Meaning Danger of fatal injury from touching electrically live components! ➤ Switch off and lock out the supply disconnecting device and check that no voltage is present. Machine starts automatically! Severe injury could result from rotating components, electrical voltage and air pres‐...
Page 31: In Emergency
Serious injury or death can result from loosening or opening component that is under pressure and heavily spring loaded! ➤ Do not open or dismantle the valve. ➤ Call for authorized KAESER Service representative if a fault occurs. Serious injury or death can result from loosening or opening component under pres‐ sure! ➤...
Page 32: Remove Any Compressor Cooling Oil From Your Person
■ incorrect repair. Correct maintenance and repair includes the use of original spare parts and operating materials. ➤ Obtain confirmation from KAESER that your specific operating conditions are suitable. Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 33: Environmental Protection
Safety and Responsibility 3.10 Environmental Protection 3.10 Environmental Protection ➤ Store and dispose of operating materials and replaced parts in accordance with local environ‐ mental protection regulations. ➤ Observe relevant national regulations. This applies particularly to parts contaminated with cooling oil. ➤...
Page 34: Design And Function
Design and Function Enclosure 4 Design and Function Enclosure Fig. 5 Enclosure Control cabinet door Latch Panel (removable) The enclosure, when closed, serves various functions: ■ sound insulation ■ protection against contact with components ■ cooling air flow control Safe and reliable operation is only assured with the enclosure closed. Access doors are hinged to swing open and removable panels can be lifted off.
Page 35: Fig. 6 Machine Layout
Design and Function Functional Description of the Machine Fig. 6 Machine layout Inlet valve Control cabinet Minimum pressure/check valve Oil separator tank Drive motor Air filter Oil filter Oil/air cooler Airend Add-on cabinet for refrigeration dryer 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 36: Refrigeration Dryer
Design and Function Refrigeration dryer Refrigeration dryer Fig. 7 Refrigeration dryer Refrigeration dryer Cyclone separator Condensate drain The centrifugal separator removes liquid condensate from the compressed air. The downstream refrigeration dryer removes moisture from the compressed air. The condensate is removed from the dryer by the condensate drains. Floating relay contacts Floating relay contacts are provided for the transfer of signals, messages.
Page 37: Cooling Air Filter Mat
Design and Function Options 4.5.2 Option K3 Cooling air filter mat The mat filters the cooling air and keeps the cooler surface clean. Fig. 9 Cooling air filter mat (option K3) Cooling air filter mat 4.5.3 Option W1/W2/W3 Heat Recovery Option W1 Prepared for external heat recovery Connections are provided and bridged.
Page 38: Operating States And Control Modes
The airend delivers compressed air to the compresses air system. The load and power consumption of the drive motor rises and falls with the air demand. The regulating valve is factory set. Consult with authorized KAESER Service representative be‐ fore making alterations. 4.6.2 Control modes Using the selected control mode, the controller switches the compressor between its various opera‐...
Page 39: Refrigeration Dryer Control Modes
Design and Function Refrigeration Dryer Control Modes The shorter these time settings, the sooner (and more frequently) the motor stops. VARIO The VARIO mode is based on the DUAL control mode. The difference from DUAL being that, under VARIO, the idling to stop time is automatically varied in order to keep the number of motor starts per hour (starting frequency) within the prescribed limits.
Page 40: Safety Devices
Design and Function Safety Devices Safety Devices The following safety devices are provided and may not be modified in any way: ■ «EMERGENCY STOP» button, The «EMERGENCY STOP» button shuts down the machine immediately. The motor remains stopped. The pressure system is vented. ■...
Page 41: Fig. 12 Indicators
Design and Function SIGMA CONTROL Keys and Indicators Item Description Function «enter» Only affects the value in the third line of the display. Enters the selected menu option. Exits the edit mode and saves. «Events and Displays the event memory. information»...
Page 42: Installation And Operating Conditions
The distances quoted are recommended distances and ensure unhindered access to all ma‐ chine parts. ➤ Please consult KAESER if they cannot be adhered to. Precondition The floor must be level, firm and capable of bearing the weight of the machine.
Page 43: Ensure Adequate Ventilation
Installation and Operating Conditions Installation Conditions Fig. 13 Recommended installation and dimensions [inch] Exhaust fan Exhaust air duct Cooling air inlet aperture CAUTION Ambient temperature too low! Frozen condensate and highly viscous cooling oil can cause damage when starting the machine. ➤...
Page 44: Using The Compressor To Supply A Compressed Air System
Installation and Operating Conditions Using the Compressor to Supply A Compressed Air System. ➤ Consult the KAESER service representative before deciding on: ■ the design of the exhaust air ducting ■ the intersection between the machine and the exhaust air duct ■...
Page 45: Installation Safety
Installation Safety 6 Installation Safety The following instructions must be followed for safe installation. Warning instructions are always given before a potentially dangerous action. Basic Safety Instructions 1. Follow the instructions in chapter 3 'Safety and Responsibility'. 2. Installation work may only be carried out by authorized personnel. 3.
Page 46: Connecting The Condensate Drain
Installation Connecting the condensate drain Fig. 14 Compressed air connection Axial compensator or hose Shut-off valve WARNING Serious injury or death can result from loosening or opening components under pressure. ➤ Vent all pressurized components and chambers completely. 1. A shut off valve must be installed by the user in the connection line. 2.
Page 47: Making The Power Supply Connection
Installation Making the Power Supply Connection ➤ Collect condensate in a suitable container and dispose of in accordance with environmental regulations. Further information The dimensional drawing in chapter 13.3 gives the size and position of the condensate drainage connection ports. Making the Power Supply Connection This is a Tri-Voltage machine.
Page 48: Tab. 14 Drive Motor
Installation Making the Power Supply Connection The following parts have to be considered for making the change: ■ Jumpers in the drive motor terminal box ■ Jumpers in the fan motor terminal box ■ Drive motor overload protection relay ■ Fan motor protection switch ■...
Page 49: Refrigeration Dryer: Connecting The Transformer According To The Power Supply
Installation Refrigeration dryer: Connecting the transformer according to the power supply. Option T2 Connecting the dryer transformer Power for the refrigeration dryer (if one is present) is provided by a transformer. This is not required for 460 V power supply. Do only use terminal 0V–208V–230V (primary side of the transformer) for changing the main voltage connection.
Page 50: Initial Start-Up Safety
Initial Start-up Safety 7 Initial Start-up Safety The following instructions must be followed for safe machine commissioning. Warning instructions are always given before a potentially dangerous action. Basic safety instructions 1. Follow the instructions in chapter 3 'Safety and Responsibility'. 2.
Page 51: Checking Installation And Operating Conditions
➤ Change the oil filter. ➤ Change the oil separator cartridge. ➤ Change the cooling oil. ➤ Have the motor bearings checked by an authorized KAESER Service rep‐ resentative. 36 months ➤ Have the overall technical condition checked by an authorized KAESER Service representative.
Page 52: Setting The Overload Protection Cut-Out
➤ Set up the overload protection cut-out. The overload cut-out drops out despite being correctly set? ➤ Contact authorized KAESER Service representative. Setting the Motor Overload Protection Switch In direct on-line starting, the current for the fan motor is fed via the motor overload protection switch.
Page 53: Check Direction Of Rotation
Initial Start-up Check Direction of Rotation 1. Unscrew the filler plug from the inlet valve. 2. Pour the stipulated amount of cooling oil into the airend and replace the filler plug. Fig. 17 Coupling Airend Safety screen Coupling Arrow showing direction of rotation 1.
Page 54: Setting The Setpoint Pressure
Initial Start-up Setting the Setpoint Pressure 5. Press the «ON» key. Machine ON lights and the machine runs in IDLE. This ensures that cooling oil The green LED is distributed throughout the machine. 6. After allowing the machine to IDLE for at least 1 minute: Press the «LOAD/IDLE»...
Page 55: Fig. 18 Label: Changing The Display Language
Initial Start-up 7.10 Changing the display language Fig. 18 Label: Changing the display language If required: Press «Enter» to enter language selection. Unlatch the EMERGENCY STOP button. Press the «UP» or «DOWN» keys as often If required: as necessary to reach the required language. Acknowledge alarm message.
Page 56: 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. The power supply disconnecting device has been installed by the user. Fig. 19 Switching on and off Machine ON (green) Key «OFF»...
Page 57: Switching Off In An Emergency And Switching On Again
Operation Switching Off in an Emergency and Switching On again 3. Switch off and lock out the power supply disconnecting device. Controller ON LED extin‐ The machine is switched off and isolated from the power supply. The guishes. Switching Off in an Emergency and Switching On again The EMERGENCY STOP pushbutton is located below the control panel.
Page 58: Switching On And Off With The Clock
Operation Switching On and Off with the Clock Fig. 21 Switching on and off in remote «remote control» key remote control LED 1. Attach an easily seen notice that warns of remote machine operation. DANGER! This machine is remotely controlled and can start automatically at any time. Tab.
Page 59: Acknowledging Alarm And Warning Messages
Operation Acknowledging Alarm and Warning Messages Fig. 22 Switching on and off with the clock «clock» key clock key 1. Attach an easily seen notice warning of time-controlled operation: DANGER! This machine is time-controlled and can start automatically at any time. Tab.
Page 60: Fig. 23 Acknowledging/Resetting Messages
Operation Acknowledging Alarm and Warning Messages Fig. 23 Acknowledging/resetting messages warning (yellow) LED alarm (red) LED «acknowledge/reset» key Alarm message Precondition Fault has been rectified ➤ Reset the message with the «acknowledge/reset» key. alarm LED extinguishes. The machine is now ready to start again. Warning message Precondition The danger of an alarm is eliminated.
Page 61: Fault Recognition And Rectification
The messages valid for your machine are dependant on the controller and individual equipment. 1. Do not attempt fault removal measures other than those given in this manual. 2. In all other cases: have the fault rectified by an authorized KAESER Service representative agent. Alarm messages (machine shut-down) Message...
Page 62 2 ext. message 3 ext. message 4 ext. message 5 Frequency converter faulty. Call authorized KAESER Service representative. back press. stop Back pressure in the oil separator tank Check venting line. caused by defective venting.
Page 63 M4 I ↥ Overload shut-down of the third fan Investigate cause of shut-down. motor. Reset overload protection cut-out. Call authorized KAESER Service representative. fan M7 I ↥ Overload shut-down of the control Investigate cause of shut-down. cabinet fan motor.
Page 64: Warning Messages (Yellow Led Lights)
The bus link from the Profibus DP Check bus highway and plug. interface is interrupted. PD temperature ↓ Package discharge (PD) tempera‐ Call authorized KAESER Service represen‐ ture too low. tative. PD temperature ↑ Package discharge (PD) tempera‐ Clean the cooler.
Page 65 Check maximum cable length and screen‐ ing. 1 master and 1 slave configured. error SMS SMS can not be sent. Call authorized KAESER Service represen‐ tative. ext. message 0 Customer specific: – ext. message 1 no details possible.
Page 66 Clean the motor. Keep ambient conditions within specified limits. motor bearings Drive motor bearing defective. Call authorized KAESER Service represen‐ tative. motor starts /h ↥ The permissible number of motor Extend the idle period. starts was exceeded in the last Increase the capacity of air receiver.
Page 67 Data retention battery is almost Change the battery. discharged. error: RAM Internal RAM defective. Call authorized KAESER Service represen‐ tative. oil content ↑ The oil content limit for pure air will Check the scavenge tube in the oil separator soon be reached.
Page 68: Other Faults
Fault Recognition and Rectification Other Faults Message Possible cause Remedy TRAP interrupt System message: Call authorized KAESER Service represen‐ TRAP interrupt tative. ADT ↑ Airend discharge temperature has Clean the cooler. almost reached maximum. Check the cooling oil level. Replace the oil filter.
Page 69: Tab. 46 Other Faults And Actions
Oil cooler leaking. Call authorized KAESER Serv‐ ice representative. Leaking joints. Tighten joints. Replace seals. Cooling oil consumption too Unsuitable oil is being used.
Page 70: 10.1 Maintenance
Maintenance 10.1 Safety 10 Maintenance 10.1 Safety The following instructions must be followed for safe machine maintenance. Warning instructions are always given before a potentially dangerous action. Basic safety instructions 1. Follow the instructions in chapter 3 'Safety and Responsibility'. 2.
Page 71: Resetting Maintenance Interval Counters
Maintenance 10.2 Maintenance Schedule ➤ Keep a log of all maintenance and repair work. This enables the frequency of individual maintenance tasks and deviations from our recommen‐ dations to be determined. Further information A prepared list is provided in chapter10.19. 10.2.2 Resetting maintenance interval counters According to the way a machine is equipped, sensors and/or maintenance interval counters monitor...
Page 72: Cooling Oil Changing Interval
Machine utilization and ambient conditions are important criteria for the number and length of the change intervals. Authorized KAESER Service representative will support you in determining appropriate inter‐ vals and provide information on the possibilities of oil analysis. ➤ Please observe national regulations regarding the use of cooling oil in oil-injected screw com‐...
Page 73: Cooler: Cleaning Or Renewing The Filter Mats
Maintenance 10.3 Cooler: Cleaning or Renewing the Filter Mats ➤ Carry out service tasks punctually taking ambient and operating conditions into account. Interval Service task Up to 12,000 h Check the valves Up to 12,000 h, at the lat‐ Check the drive motor and fan motor bearings. est every 3 years Up to 36,000 h, at the lat‐...
Page 74: Cleaning Or Replacing The Control Cabinet Filter Mats
Maintenance 10.4 Cleaning or Replacing the Control Cabinet Filter Mats 10.4 Cleaning or Replacing the Control Cabinet Filter Mats Filter mats protect the control cabinet from ingress of dirt. If the filter mats are clogged, adequate cooling of the components is no longer ensured. In such a case, clean or replace the filter mats. Material Warm water and household detergent Spare parts (as required)
Page 75: Heat Recovery System Maintenance
➤ Dry brush the oil and air coolers and use a vacuum cleaner to suck up the dirt. The air and oil coolers can no longer be properly cleaned? ➤ Heavy and stubborn contamination should be removed by a KAESER Service representa‐ tive.
Page 76: External Heat Recovery
2. Have an authorized KAESER Service representative check the heat exchanger for internal leaks at least once a year. Contamination ➤ Have an authorized KAESER Service representative clean the heat exchanger as soon as a pressure drop in the heat transfer medium is detected. 10.7 Air Filter Maintenance Do not clean the air filter element with liquids.
Page 77: Motor Maintenance
6. Switch on the power supply disconnecting device and reset the maintenance interval counter. 10.8 Motor Maintenance The drive motor bearings are permanently greased. Subsequent greasing is not necessary. Drive motor ➤ Have the motor bearings checked by the KAESER Service representative. Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
Page 78: Checking The Coupling
Maintenance 10.9 Checking the Coupling Fan motor ➤ Have the motor bearings checked by a KAESER Service representative. 10.9 Checking the Coupling A defective coupling is recognizable by: ■ noisy running, ■ surface cracks, ■ color change. WARNING Danger of injury from rotating coupling! ➤...
Page 79: Checking The Safety Relief Valve
The machine should shut down if the airend discharge temperature reaches a maximum of 230 °F. ➤ Check the safety shutdown function as described in the SIGMA CONTROL manual. The machine does not shut down? ➤ Have the safety shutdown function checked by an authorized KAESER Service represen‐ tative. 10.12 Checking the cooling oil level The oil level can be seen through the window in the front inspection door.
Page 80: Venting The Machine (Depressurizing)
Maintenance 10.13 Venting the machine (depressurizing) Fig. 29 Checking the cooling oil level Minimum oil level Maximum oil level Optimum level ➤ Check the oil level with machine running. Result Top up when the indicator shows minimum level. 10.13 Venting the machine (depressurizing) The machine must be isolated from the compressed air system and completely vented before undertaking any work on the pressure system.
Page 81: Fig. 30 Venting The Machine
➤ If manual venting does not bring the oil separator tank pressure gauge to 0 psig, call an authorized KAESER Service representative. Vent air manually from the air cooler. After shutting down the compressor and venting the oil separator tank, there is still pressure on the machine from the compressed air system or in the section from the shut-off valve to the minimum pressure/check valve.
Page 82: Topping Up The Cooling Oil
Maintenance 10.14 Topping up the Cooling Oil 2. Slowly open the shut-off valve to release pressure. 3. Withdraw the male hose fitting and close the shut-off valve 10.14 Topping up the Cooling Oil The machine must be isolated from the compressed air system and completely vented before undertaking any work on the pressure system.
Page 83: Top Up With Cooling Oil And Test Run
➤ If manual venting does not bring the oil separator tank pressure gauge to 0 psig, call an authorized KAESER Service representative. Vent air manually from the air cooler After shutting down the compressor and venting the oil separator tank, there is still pressure on the machine from the compressed air system or in the section from the shut-off valve to the minimum pressure/check valve.
Page 84: Changing The Cooling Oil
➤ Always change the oil filter and oil separator cartridge when changing the oil. ➤ Contact KAESER Service representative if condensate is detected in the cooling oil. It is necessary to adjust the airend discharge temperature to suit operating conditions.
Page 85: Fig. 32 Changing The Cooling Oil, Oil Separator Tank
Maintenance 10.15 Changing the Cooling Oil Fig. 32 Changing the cooling oil, oil separator tank Hose coupling (air cooler venting) Shut-off valve open Pressure gauge Shut-off valve closed Hose coupling (oil separator tank venting) Maintenance hose Oil filler port with plug Hose coupling (oil drain) Cooling oil level indicator Shut-off valve (venting line)
Page 86: Fig. 33 Changing The Cooling Oil, Oil Cooler
Maintenance 10.15 Changing the Cooling Oil 3. Place the end of the maintenance hose in the oil receptacle and secure it in place. 4. Open the shut-off valve 5. Slowly open the shut off valve in the maintenance hose to release oil and close immediately when air escapes.
Page 87: Fig. 34 Changing The Cooling Oil, Airend
Maintenance 10.15 Changing the Cooling Oil Draining the oil from the airend Fig. 34 Changing the cooling oil, airend Compressed air outlet on airend Safety screen Hose coupling (oil drainage) Coupling Shut-off valve 1. Have an oil receptacle ready. 2. With the shut-off valve closed, insert the male hose fitting into the hose coupling 3.
Page 88: Changing The Oil Filter
Maintenance 10.16 Changing the Oil Filter Fig. 35 Changing the cooling oil, heat recovery system Hose coupling Thermostatic valve Shut-off valve 1. Have an oil receptacle ready. 2. Insert the male hose fitting (from 32) in the hose coupling 3. Place the end of the maintenance hose in the oil receptacle and secure it in place. 4.
Page 89: Changing The Oil Separator Cartridge
Maintenance 10.17 Changing the Oil Separator Cartridge WARNING There is risk of burns from hot components and oil. ➤ Wear long-sleeved clothing and gloves. Fig. 36 Changing the oil filter Oil filter Direction to unscrew Changing the oil filter 1. Unscrew the oil filter counter-clockwise, catch oil spillage and dispose of in accordance with environmental protection regulations.
Page 90: Fig. 37 Changing The Oil Separator Cartridge
Maintenance 10.17 Changing the Oil Separator Cartridge The life of the oil separator cartridge is influenced by: ■ contamination in the air drawn into the compressor, ■ adherence to the changing intervals for: ─ cooling oil ─ oil filter ─ air filter Material Replacement part...
Page 91: Refrigeration Dryer Maintenance
Maintenance 10.18 Refrigeration Dryer Maintenance 8. Attach the air pipe to the cover with a new, self-locking nut. 9. Replace and tighten all fittings. ➤ Dispose of parts and materials contaminated with oil in accordance with environmental protection regulations. Start the machine and carry out a test run 1.
Page 92: Checking Condensate Drainage
Maintenance 10.18 Refrigeration Dryer Maintenance 2. Use compressed air (<70 psig) to blow the condenser through from outside to inside and then vacuum up the dirt. 3. Replace the panel again. 10.18.2 Checking condensate drainage The LED lights as soon as condensate begins to drain. Precondition Machine running under LOAD Fig.
Page 93: Fig. 40 Condensate Drain Maintenance
Maintenance 10.18 Refrigeration Dryer Maintenance Fig. 40 Condensate drain maintenance Service unit Snap fastener Control unit Drain hose fitting Sensor Contact spring Sensor opening Inlet Removing the service unit 1. Close the shut-off valve upstream of the condensate drain. 2. Unscrew the drain hose fitting. 3.
Page 94: Document Maintenance And Service Work
Maintenance 10.19 Document maintenance and service work. 10.19 Document 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. 50 Logged maintenance tasks Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 95: 11 Spares, Operating Materials, Service
➤ Please give the information from the nameplate with every inquiry and order for spares. 11.2 Ordering Consumable Parts and Operating Materials KAESER consumable parts and operating materials are all genuine KAESER parts. They are selected for use in KAESER machines. WARNING There is risk of personal injury or damage to the machine resulting from the use of unsuitable spare parts or operating materials.
Page 96: Service Addresses
Service Addresses 11.4 Service Addresses Addresses of KAESER representatives are given at the end of this manual. 11.5 Spare Parts for Service and Repair With the help of this parts list you can plan your material requirement according to operating conditions and order the spare parts you need.
Page 97 Spares, Operating Materials, Service 11.5 Spare Parts for Service and Repair Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
Page 98 Spares, Operating Materials, Service 11.5 Spare Parts for Service and Repair Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 99: 12 Decommissioning, Storage And Transport
2. Disconnect all air and electrical connections. 12.2 Packing A wooden crate is required for ground transport to protect the machine from mechanical damage. Consult an authorized KAESER Service representative for advice on packing for sea or air transport. Material Desiccant Plastic sheeting...
Page 100: Transporting
Decommissioning, Storage and Transport 12.4 Transporting CAUTION Machine damage from moisture and frost. ➤ Prevent ingress of moisture and condensation. ➤ Maintain >32 °F storage temperature. ➤ Store the machine in a dry, frost-proof room. 12.4 Transporting 12.4.1 Safety Weight and center of gravity determine the suitable transporting method. The center of gravity is shown in the drawing in chapter 13.3.
Page 101: Disposal
Decommissioning, Storage and Transport 12.5 Disposal Fig. 42 Transporting with a crane CAUTION Machine damage by incorrect lifting cradle attachment. ➤ Do not attach the lifting cradle to any of the machine components. ➤ The machine manufacturer can advise on application of a suitable lifting cradle. ➤...
Page 102: 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) Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 103 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
Page 104 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 105 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
Page 106 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 107 Annex 13.1 Pipeline and instrument flow diagram (P+I diagram) Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
Page 108 Annex 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode 13.2 Option C1 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 109 Annex 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
Page 110 Annex 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 111 Annex 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
Page 112 Annex 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 113 Annex 13.2 Pipe and Instrument Flow Diagram (P+I diagram): MODULATING control mode Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
Page 114 Annex 13.3 Dimensional Drawing 13.3 Dimensional Drawing Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
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Page 116 Annex 13.3 Dimensional Drawing Service Manual Screw Compressor ASD T Tri-Voltage 9_5721 06 USE...
Page 117 Annex 13.4 Electrical Diagram 13.4 Electrical Diagram Service Manual Screw Compressor 9_5721 06 USE ASD T Tri-Voltage...
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KAESER ASD T Series Service Manual

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