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 alert notes and their symbols ..............Technical Data Nameplate ........................Options ..........................Weight ..........................Ambient conditions ......................
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Contents 4.7.6 "Information" menu ..................... 4.7.7 Service menu ...................... Options ..........................4.8.1 Floating relay contact "Refrigeration compressor runs" ........4.8.2 Pressure dew point warning ................4.8.3 MODBUS TCP communication module .............. 4.8.4 Machine Mountings ..................... 4.8.5 Transformer power supply .................. 4.8.6 High ambient temperature.
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Contents 10.4.2 Changing the service unit ................... Spares, Operating Materials, Service 11.1 Note the nameplate ......................11.2 Spare Parts and Operating Materials ................11.3 KAESER AIR SERVICE ....................11.4 Replacement parts for service and repair ................ Decommissioning, Storage and Transport 12.1 Decommissioning ......................
Regarding this Document Using this document 1 Regarding this Document Using this document The operating manual is a component of the product. It describes the machine as it was at the time of first delivery after manufacture. ➤ Keep the operating manual in a safe place throughout the life of the machine. ➤...
Regarding this Document Symbols and labels The type and source of the imminent danger is shown here! The possible consequences of ignoring a warning are shown here. The word "DANGER" indicates that death or severe injury can very likely result from ignoring the warning.
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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. The conditional requirements relevant to safety shown here will help you to avoid dangerous situa‐ tions.
Technical Data Nameplate 2 Technical Data Nameplate Machine nameplate The model designation and important technical information are provided on the machine's name‐ plate. The nameplate is located on the outside of the machine. Nameplates in various languages are provided with the machine. ➤...
Technical Data Options The heat exchanger’s nameplate is attached directly at the heat exchanger within the machine. Fig. 1 Heat exchanger nameplate Heat exchanger Nameplate Insulation 1. Carefully pull out and remove the insulation 2. Read the data on the nameplate 3.
Technical Data MODBUS TCP communication module TE 102 TE 122 TE 142 Refrigerant R-513A R-513A R-513A Global warming potential (GWP) 3.31 3.42 3.42 Charge quantity [lb] Charge quantity as CO equivalent [t] Maximum working pres‐ sure [psig] (high pressure end) Maximum working pres‐...
Value Power supply [V DC] Tab. 10 Additional data, communication interface Noise emission [dB(A)] TE 102 TE 122 TE 142 Noise emission Noise pressure level as per EN ISO 11203 and basic standard ISO 9614-2 with d=1 m and Q2=15.7 dB(A), uncertainty: ±3 dB(A) Tab.
It is recommended to use a ground conductor the same size as the current carrying conductors, if local codes allow. Neither the minimum ground wire size as pointed out in 2020 NEC table 250.122 nor using conduit as the sole ground connection is recommended. Performance data TE 102 TE 122 TE 142 2.01 2.55...
Technical Data 2.10 Power supply specifications TE 102 TE 122 TE 142 Consumption [A] 12.3 Tab. 13 Power supply details 208V / 3ph / 60Hz Rated voltage: 230V / 3ph / 60Hz TE 102 TE 122 TE 142 Pre-fuse [A]...
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, ■...
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.
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Safety and Responsibility Dangers ➤ 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‐ trical engineering regulations. ➤ Before commissioning or re-commissioning the machine, the user must make sure there is ad‐ equate protection against electric shock from direct or indirect contact.
Safety and Responsibility Dangers ➤ Do not inhale refrigerant mist and vapours. ➤ Do not eat or drink while handling refrigerant. ➤ Keep suitable fire extinguishing agents ready for use. ➤ Allow only qualified specialists to work on refrigerant circuits. ➤...
Safety and Responsibility Dangers ➤ If installed outdoors, the machine must be protected from frost, direct sunlight, dust, rain, and splashing water. ➤ Do not operate in areas in which specific requirements with regard to explosion protection are in force. ➤...
Safety and Responsibility Safety devices 3.5.4 Danger Areas The table gives information on the areas dangerous to personnel. Only authorized personnel may enter these areas. Activity Danger area Authorised personnel Transport Within a 10 ft. radius of the machine. Installation personnel for transport preparation.
Safety and Responsibility Emergency situations Fig. 4 Location of safety signs Item Sign Meaning Injury and/or machine defects by improper use! ➤ Maintenance should be performed by properly trained personnel only. ➤ Read and understand manual and all safety labels before switching the ma‐ chine on.
Safety and Responsibility Warranty ➤ Shut off supply lines if possible. Power supply disconnecting device (all phases) Cooling water (if present) ➤ Warn and move endangered personnel to safety. ➤ Help incapacitated persons. ➤ Close the doors. ➤ When trained accordingly: Attempt to extinguish the fire. Extinguishing substances ➤...
Safety and Responsibility 3.10 Environment protection A condition of our warranty is that the machine is used for the purpose for which it is intended un‐ der the conditions specified. Due to the multitude applications for which the machine is suitable the obligation lies with the user to determine its suitability for his specific application.
Design and Function Enclosure 4 Design and Function Enclosure Fig. 5 Enclosure overview Control cabinet door Latch Access panel Maintenance opening The enclosure, when closed, serves various functions: ■ Sound insulation ■ Protection against contact with components ■ Cooling air flow The enclosure is not suitable for the following uses: ■...
Design and Function Operating modes and control modes Fig. 6 Machine overview Compressed air inlet Refrigerant compressor Control cabinet Compressed air outlet Refrigerant condenser Controller operator panel Heat exchanger with condensate separa‐ Pressure monitor Power supply disconnecting device (main Condensate drain switch) Stage 1: Warm compressed air entering the first section of the heat exchanger gives up some of its heat to...
Design and Function SECOTEC CONTROL ■ The machine is switched off. ON indicator is extinguished. ■ READY The machine has been activated with «ON»: ON indicator lights green. ■ ■ The refrigerant compressor is switched off. The refrigerant compressor starts as soon as the start conditions are met. LOAD The start conditions are met: ■...
Design and Function Safety devices Indication Operational state Function Fault/alarm Fault occurred Alarm Valve opens and closes repeatedly in an attempt to clear Power Service the fault. Test of the valve function For manual draining, press and hold the button for about 2 seconds.
Design and Function SIGMA CONTROL SMART Item Name Function «Remote control» Switches the remote control on and off. «Up» Scrolls up the menu options. Increases a parameter value. «Down» Scrolls down the menu options. Reduces a parameter value. «Enter» Jumps to the selected menu option. Switches to Edit mode.
Design and Function SIGMA CONTROL SMART Indicators Fig. 9 Indicators Item Name Function Controller voltage Lights green when the power supply is switched on. Alarm Flashes red when an alarm occurs. Lights continuously when acknowledged. Warning/ Continuous yellow light indicates a warning or maintenance message. Maintenance Remote control Continuous yellow light when remote control is activated.
Design and Function SIGMA CONTROL SMART 4.7.2 User operation SIGMA CONTROL SMART Handling concept Task Procedure Navigating For navigating the menus, a cursor is provided to move the «UP» and «DOWN» the menu keys The current cursor position is indicated by inverse coloring. Use the «Enter»...
Design and Function SIGMA CONTROL SMART Item Designation Description <Service> Displays maintenance tasks to be performed and the maintenance timer. Tab. 25 Main menu Color concept Different colors indicate the various operating states. Color Meaning White Component is shut down. For sensors: The activation criteria is not met Green Component is switched on.
Design and Function SIGMA CONTROL SMART 4.7.4 Messages menu All messages reported in the past are listed and displayed in the color of their classification: ■ Warning/maintenance message: Yellow ■ Alarm message: Red Fig. 12 Event history <Messages> Operating hour during which the message Additional navigation options: had been issued the last time (example: Escape...
Design and Function SIGMA CONTROL SMART 4.7.5 "Flow diagram" menu Fig. 13 Flow diagram <Flow diagram> Refrigerant condenser Expansion valve: thermostatic Refrigerant compressor Temperature transducer (pressure dew Run time of the refrigerant compressor in point) the current cycle (here: 67 s) Pressure transducer (condensation pres‐...
Design and Function SIGMA CONTROL SMART Fig. 14 Information: Screen 1 Number of operating hours during which Number of operating hours of the refriger‐ the controller is under power (here: ant compressor (here: 1867 h) 6000 h) Number of operating hours of the fan motor Number of operating hours during which (here: 1240 h) the machine was switched on (here:...
Design and Function SIGMA CONTROL SMART 4.7.6.3 Screen 3 Use «DOWN» to open the next screen. Fig. 16 Information: Screen 3 Units of measure used (here: °C) Condensate drain: Activate fault message Installation altitude (here: 500 m) (here: Fault message activated) Electric energy saved with "eco"...
Design and Function SIGMA CONTROL SMART Fig. 17 Screen 1: Condensate drain Start value of the maintenance counter (here: 8760 h) Remaining operating hours to the next due maintenance (here: 1438 h) Resetting the maintenance interval counters: activate/deactivate To reset the maintenance hours counter to its start value, activate the check box and confirm with «Enter».
Design and Function Options Options The options available for your machine are described below. 4.8.1 Option C37 Floating relay contact "Refrigeration compressor runs" This floating relay contact switches as soon as the refrigerant compressor runs. 4.8.2 Option C36 Pressure dew point warning This floating relay contact switches as soon as the pressure dew point exceeds the permissible range.
Design and Function Options 4.8.3.1 Display and operating elements of the communications module The plug-in communications module communicates with SIGMA CONTROL SMART (SCS) via CAN bus (X2). The plug-in communications module is equipped with these operating elements, displays and con‐ nections: Fig.
Design and Function Options Item Designation Color Status Description – – – Pin 1 RESET key in housing – – Pressing the key with a suitable object for underneath opening more than 3 s will reset the IP settings (IP address, SubNetMask, Gateway) to the factory setting Tab.
Installation and Operating Conditions Ensuring safety 5 Installation and Operating Conditions Ensuring safety The conditions in which the machine is installed and operated have a decisive effect on safety. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety warnings Disregard of safety warnings can cause unforeseeable dangers! ➤...
Installation and Operating Conditions Installation conditions Fig. 22 Recommended machine placement and dimensions [in.] Cooling air inlet Cooling air outlet Ambient temperature too low! Frozen condensate can damage the machine. ➤ Switch the machine on only when the switch-on temperature is reached. 2.
Installation and Operating Conditions Operating the machine in a compressed air network 5.2.3 Exhaust duct design The machine can only overcome the air resistance at the cooling air inlet and exhaust determined by the duct design. Any additional air resistance will reduce airflow and deteriorate machine cool‐ ing.
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 warnings Disregard of safety warnings can cause unforeseeable dangers! ➤...
Installation Reporting Transport Damage Reporting Transport Damage 1. Check the machine for visible and hidden transport damage. 2. Inform the carrier and the manufacturer in writing of any damage without delay. Making the compressed air connection Condensate in the compressed air network can damage the pipework: ➤...
Installation Connecting the condensate drain Connecting the condensate drain A threaded hose connection is provided to attach a condensate drain hose. The condensate must be able to drain freely. ➤ Only machines with 232 psig maximum permissible working pressure may be connected to the condensate collecting line.
Installation Connecting the machine with the power supply Compressed air flow Line cross-section ["] rate [cfm] < 350 350 – 705 706 – 1410 1 1/2 > 1410 Compressed air flow rate as guide for the condensate volume to be expected Tab.
Installation Options 3. Test the overcurrent protection cut-out (backup fuse) to ensure that the time it takes to discon‐ nect in response to a fault is within the permitted limit. 4. Select supply cable conductor cross-sections and fusing in accordance with local regulations. 5.
Initial Start-up Ensuring safety 7 Initial Start-up Ensuring safety Here you will find instructions for a safe initial startup of the machine. Warning instructions are located before a potentially dangerous task. Disregard of warning instructions can cause serious injuries! Complying with safety warnings Disregard of safety warnings can cause unforeseeable dangers! ➤...
Initial Start-up Instructions to be observed before commissioning or re-commissioning Instructions to be observed before commissioning or re-commis‐ sioning Incorrect or improper commissioning can cause injury to persons and damage to the machine. ➤ Commissioning may only be carried out by authorized installation and service personnel who have been trained on this machine.
Initial Start-up Checking the direction of rotation To be checked Confirmed? chapter ➤ Are all access doors closed and latched and removable panels in – place and secured? Tab. 32 Installation conditions checklist Checking the direction of rotation The machine is designed for a clockwise phase sequence. The direction of phase rotation should be measured with a phase sequence meter.
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Initial Start-up Starting the machine for the first time Connection to a SIGMA NETWORK Connection to the user's Modbus TCP network 1. Register the machine with SCS at 1. Register the machine as a Modbus TCP de‐ SIGMA AIR MANAGER 4.0. The IP address vice at the user's Modbus TCP bus master is transmitted to SCS.
Operation Switching the machine on and off 8 Operation Switching the machine on and off Always switch the machine on via the «ON» key and off via the «OFF» key. The machine is connected to or disconnected from the power supply via the power supply discon‐ necting device.
Operation Using the remote control 8.1.2 Switching off 1. Press the «OFF» key. ON indicator flashes. The machine gently shuts down. The 2. Press the «OFF» key again to immediately shut the machine down. 3. Switch off and lock out / tag out the power supply disconnecting device. 4.
Operation Acknowledging and Resetting Warning and Alarm Messages 2. Press the «“Remote”» key [1]. Remote control display [2] illuminates yellow. You can The remote control is switched on, the switch the machine in the remote control center between the READY and STOP operating points.
Fault Recognition and Rectification Basic instructions 9 Fault Recognition and Rectification Basic instructions The alarm indications valid for your machine are dependent on the individual equipment. 1. Do not attempt fault rectification measures other than those given in this manual! 2.
Fault Recognition and Rectification Communications module – Troubleshooting Warning messages Number Meaning Switching frequency of refrigerant compressor is high. Fault in the condensate drain. Pressure dew point is high. ■ This message is output when the yellow warning range has been reached. ■...
Fault Recognition and Rectification Other faults Item Display Fault Possible cause Measure flash‐ SCS without voltage Check the power supply es red commu‐ Communications module loose Plug in the communications 1x/s nication module and tighten the fasten‐ faulty ing screws flash‐...
Fault Recognition and Rectification Other faults Fault Possible cause Measure The pressure monitor switches Ambient or compressed air inlet Check that installation condi‐ the machine off. temperature too high. tions are OK. Refrigerant condenser dirty. Clean the refrigerant condens‐ The motor protective switch Phase loss Reset the motor protective trips..
Maintenance 10.1 Ensuring safety 10 Maintenance 10.1 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 warnings Disregard of safety warnings can cause unforeseeable dangers! ➤...
Maintenance 10.2 Regular maintenance tasks 10.2 Regular maintenance tasks The refrigeration circuit is maintenance-free. Repairs may only be carried out by certified person‐ nel. The table below lists maintenance tasks required. ➤ Carry out maintenance tasks, or have them carried out, punctually as determined by ambient and operating conditions.
Maintenance 10.4 Maintaining the condensate drain 1. Use compressed air to blow the refrigerant condenser clean at regular intervals. 2. Have stubborn clogging removed by an authorized KAESER service representative. 10.4 Maintaining the condensate drain 10.4.1 Checking the condensate drain Precondition The user's power supply isolating device (main switch) is switched on.
Maintenance 10.4 Maintaining the condensate drain Fig. 31 Changing the service unit Service unit Condensate inlet Control module Shut-off valve Sensor O-ring Sensor opening Screw-in part Snap fastener Sealing tape Screw connection (for condensate drain) Union nut with vent holes Contact springs Insulation Removing the service unit...
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Maintenance 10.4 Maintaining the condensate drain 2. Carefully insert the control module sensor in the opening of the service unit. 3. Place the snap fastener of the control module into the service unit eyes. 4. Press the control module to the service unit until the snap fastener can be heard to click into place.
Spares, Operating Materials, Service 11.1 Note the nameplate 11 Spares, Operating Materials, Service 11.1 Note the nameplate The nameplate contains all information to identify your machine. This information is essential to us in order to provide you with optimal service. ➤...
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Spares, Operating Materials, Service 11.4 Replacement parts for service and repair ➤ Make sure that any service or repair tasks not described in this manual are carried out by an authorized KAESER Service represenstative. Operator Manual Refrigerated Dryer No.: 901772 07 USE...
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Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator Manual Refrigerated Dryer No.: 901772 07 USE...
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Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Legend 5400 Refrigeration dryer TE SEL-4136_04 Item Description Option 1555 Filter dryer 1545 Refrigerant collector 1700 Refrigerant 1707 Acid test, refrigerant 1710 Refrigerant indicator 2222 Temperature sensor 2525 Injection valve...
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Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator Manual Refrigerated Dryer No.: 901772 07 USE...
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Spares, Operating Materials, Service 11.4 Replacement parts for service and repair Operator Manual Refrigerated Dryer No.: 901772 07 USE...
Decommissioning, Storage and Transport 12.1 Decommissioning 12 Decommissioning, Storage and Transport 12.1 Decommissioning Decommissioning 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.
Decommissioning, Storage and Transport 12.3 Transport Precondition Transport only by forklift truck or suitable lifting gear and only by personnel trained in the safe transportation of loads. ➤ Ensure the danger area is clear of personnel. 12.3.2 Transport with a forklift truck Precondition The forks are fully under the machine.
Decommissioning, Storage and Transport 12.4 Disposal Fig. 33 Transport with a crane Load carrying devices Attachment resources Risk of accident caused by incorrect use of lifting gear and attachment devices! ➤ Comply with permissible load limits. ➤ Comply with specific safety information of used load-carrying and attachment devices. 2.
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Decommissioning, Storage and Transport 12.4 Disposal 1. De-commission the machine. 2. Dispose of the machine through an authorized disposal service. ➤ Refrigerant and oil must be drained and disposed of by an authorized specialist work‐ shop. Operator Manual Refrigerated Dryer No.: 901772 07 USE...
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Annex 13.4 Electrical Diagram electrical component parts list TE 102 TE 122 TE 142 model machine power supply 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz 460 V ±10 %, 60 Hz...
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