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Summary of Contents for KAESER KOMPRESSOREN TCH 22
- Page 1 SERVICE MANUAL Refrigeration Dryer Model TCH No.: 9_5756_02USE...
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Page 3: Table Of Contents
Contents Chapter --- page Regarding this Document ........1 --- 1 Handling the Document . - Page 4 Contents Chapter --- page Installation and Operating Conditions ......5 --- 15 Surroundings ............5 --- 15 Installation Conditions .
- Page 5 Contents Chapter --- page 11 Spares, Operating Materials, Service ......11 --- 29 11.1 Note the nameplate .
- Page 6 Directory of Illustrations Chapter --- page Fig. 1 Warning symbols on the machine ........3 --- 9 Fig.
- Page 7 Table Directory Chapter --- page Tab. 1 Nameplate ............2 --- 2 Tab.
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Page 8: Regarding This Document
Regarding this Document Regarding this Document Handling the Document The service manual is part of the machine. Keep the service manual in a safe place throughout the life of the machine. Pass the manual on to the next owner/user of the machine. Ensure that all amendments received are entered in the manual. -
Page 9: Technical Specification
Rated current Ambient temperature Tab. 1 Nameplate Weight The weight given is the maximum. Actual weights of individual machines are dependent on equipment fitted. TCH 22 TCH 26 TCH 32 TCH 35 Weight [lb] Tab. 2 Machine weight Ambient Conditions... -
Page 10: Compressed Air System
Technical Specification Compressed Air System TCH 22 TCH 26 TCH 32 TCH 35 Pressure drop* [psi] Flow rate* [cfm] Maximum permitted working pressure [psig] Pressure dew point [˚ F] at100˚ F air inlet,100psig,100˚ F ambient temperature and 60 Hz power supply Tab. -
Page 11: Power Supply Specifications
NEC Table 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 230V 10%. 1 --- ph. 60Hz ¡ TCH 22 TCH 26 TCH 32 TCH 35 Mains fuses [A]... -
Page 12: Safety And Responsibility
Safety and Responsibility Safety and Responsibility Disregard of these instructions can result in serious injury. DANGER Read the service manual carefully and pay attention to its contents. The machine is manufactured to the latest engineering standards and acknowledged safety regulations. Nevertheless, dangers can arise through its operation: ¡... -
Page 13: Safety Devices
Safety and Responsibility Installation and maintenance personnel Authorised installation and maintenance personnel: must be adult, must have read, be conversant with and adhere to the safety instructions and sections of the service manual applicable to installation and maintenance, must be fully conversant with the safety concepts and regulations of electrical, com- pressed air engineering and refrigeration techniques, must be able to recognize the possible dangers of electrical, compressed air and re- frigeration techniques and take appropriate measures to safeguard persons and prop-... - Page 14 Safety and Responsibility Pressure forces Compressed air is a contained force. Uncontrolled release of this energy can cause seri- ous injury or death. Before all work on a pressure system: close shut–off valves or otherwise isolate the machine from the air network to ensure that no compressed air can flow back into the machine, Do not carry out welding, heat treatment or mechanical modifications to pressure com- ponents (e.g.
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Page 15: Safe Machine Operation
Safety and Responsibility 3.5.2 Safe machine operation Here is found information to support safe conduct with the machine. Transport Use suitable lifting gear that conforms to local safety regulations. Attach lifting gear only to the designated points on the machine. Note the centre of gravity to avoid the machine tipping. -
Page 16: Organisational Measures
Safety and Responsibility Decommissioning / disposal Do not damage the refrigerant circuit. Give refrigerant only to authorized bodies for disposal. Dispose of the machine in accordance with local environmental regulations. 3.5.3 Organisational measures Designate personnel and their responsibilities. Give clear instructions on reporting faults and damage to the machine. Give instructions on fire reporting and fire–fighting measures. -
Page 17: In Emergency
Safety and Responsibility In Emergency 3.7.1 Contact with refrigerant Inhalation: Remove the affected person to fresh air and make him or her rest. If breathing stops, apply artificial respiration and call for medical assistance. Skin contact: Rinse immediately with plenty of water. Treat burns and frostbite. -
Page 18: Design And Function
Design and Function Design and Function Machine Overview 4.1.1 Cabinet Fig. 2 Cabinet Panel Rear panel The cabinet, when closed, serves various functions: sound damping protection against contact cooling air flow control Safe and reliable operation is only assured with the cabinet closed. To open the cabinet, loosen the retaining screws in the front and side panels with a screw- driver and remove the panels. -
Page 19: General Design
Design and Function General Design Fig. 3 Machine overview Compressed air inlet Compressed air outlet Control cabinet Safety pressure switch Refrigerant condenser 10 Filter/dryer Heat exchanger 11 Refrigerant compressor Condensate drain 12 Hot gas bypass valve The main component in a refrigeration dryer is a combination heat exchanger (4). A condensate separating system (5) is fitted downstream of the heat exchanger. -
Page 20: Safety Devices
Design and Function Safety Devices The following safety devices are provided and may not be modified: EMERGENCY STOP The ON/OFF switch shuts down the machine immediately. It can be fitted with a padlock to prevent reapplication of power. Safety pressure switch The safety pressure switch protects the refrigerant circuit against excessive pressure. -
Page 21: Accessories
Design and Function Accessories 4.6.1 Bypass line (see chapter 6.5) The refrigeration dryer can be isolated from the air main with the bypass line. The air supply is maintained, however, no drying can take place. 4 --- 14... -
Page 22: Installation And Operating Conditions
Installation and Operating Conditions Installation and Operating Conditions Surroundings No open flames or sparks at the place of installation. Ensure that flying sparks or excessive temperatures during welding work on the ma- chine are not a fire hazard. The machine is not explosion ---proof. Do not operate in areas in which specific requirements with regard to explosion protection are applied. -
Page 23: Operating In A Compressed Air System
Installation and Operating Conditions 5.2.2 Operating in a compressed air system When the machine is connected to an air system, the operating pressure must not exceed 230 psig. Initial filling of a fully vented air system generally creates a very high rate of flow through air treatment devices. -
Page 24: Installation
Installation Installation Safety Refrigerant DANGER There is considerable risk of injury from released refrigerant if the refriger- ant circuit is incorrectly opened. Do not open the rfrigerant circuit. All functional parts are factory set. Changes may not be made without the permission of the manufacturer. Installation may only be carried out by persons fully conversant with the basic safety con- cepts of refrigeration dryers. -
Page 25: Compressed Air Connection
Installation Compressed Air Connection Pre–condition: The air main is at atmospheric pressure. 6.4.1 Shut--- off valves: Take care during installation that no strain, pressure or bending forces are acting upon the compressed air connections. Install user’s shut ---off valves on the compressed air inlet and outlet. Bypass line (accessory) 6.5.1 Bypassing the refrigeration dryer (when required) -
Page 26: Condensate Drain Line Connection
Installation Operating with bypass line Fig. 8 Operating with bypass line 10 Hose T---piece 20 Elbow --- compressed air inlet Ball valve 30 Ball valve Observe the position of the valve operating lever. Remove the plug (60 Fig.7) from the ball valve (50). Unscrew the hose (10) from the elbow (20) and screw it into the ball valve (50). -
Page 27: Initial Start
Initial Start-up Initial Start---up Safety Voltage! DANGER Contact with live electric components can cause serious injury or death. Isolate all phases of the main power supply. (switch off the mains supply disconnecting device) Ensure that the power supply cannot be switched on again (locked off). -
Page 28: Starting The Machine For The First Time
Initial Start-up Starting the Machine for the First Time Open the shut–off valve to the compressed air system. Switch on the machine. The refrigeration compressor starts and after a short period the machine cools the com- pressed air. Watch for any faults occurring during the first few hours of operation. 7 --- 21... -
Page 29: Operation
Operation Operation Fig. 9 Switching on and off On/off switch Pressure dew point indicator Switching On and Off Compressed air! Serious injury is possible. WARNING Never direct compressed air at persons or animals. 8.1.1 Switching on Ensure that: ¡ no one is working on the machine, ¡... -
Page 30: Fault Finding And Removal
Event Recognition and Fault Rectification Fault Finding and Removal Inform KAESER Service if the fault cannot be removed by the measures suggested. Do not attempt fault removal measures other than those given in this manual. Faults Fault Possible cause Remedy Water in the compressed Compressed air inlet and Check the compressed air... -
Page 31: Maintenance
Maintenance Maintenance 10.1 Safety Any disregard of these instructions and/or incorrect handling may result in serious injuries. Voltage! DANGER There is danger of fatal injury caused by touching electrically live compo- nents. Isolate all phases of the main power supply. (switch off the mains supply disconnecting device) Ensure that the power supply cannot be switched on again (locked off). -
Page 32: Cleaning The Refrigerant Condenser
Maintenance 10.2.2 Cleaning the refrigerant condenser Fig. 11 Cleaning the refrigerant condenser andcondensate drain Condensate drain Refrigerant condenser Equipment: Compressed air for blowing out Cleaning rags Water with cleaning agent additive Pre–condition: Machine switched off. Supply disconnecting device switched off and locked out. Machine cooled down. -
Page 33: Checking Condensate Drainage
Maintenance 10.2.3 Checking condensate drainage Pre–condition: Machine running. Fig. 12 Testing the condensate drain TEST button Check visually that condensate flows from the drain hose. Condensate does not drain out? The condensate drain hose is clogged. Switch off the machine and clean or replace the drain hose. Condensate does not drain out? Condensate drain blocked. -
Page 34: Cleaning The Condensate Drain
Maintenance 10.2.4 Cleaning the condensate drain Equipment: Compressed air for blowing out Cleaning rags Spare parts (as required) Pre–condition: Machine switched off. Supply disconnecting device switched off and locked out. Close the shutoff valve in the line to the ECO DRAIN. Machine cooled down. -
Page 35: Logging Maintenance Work
Maintenance 10.3 Logging Maintenance Work Machine number: Date Maintenance task carried out Operating hours Signature Tab. 12 Maintenance log 10 --- 28... - Page 36 Spares, Operating Materiels, Service Spares, Operating Materials, Service 11.1 Note the nameplate Please quote the data on the nameplate for all enquiries and spare parts orders. 11.2 Ordering Consumable Parts and Operating Materials Personal injury or damage to the machine may result from the use of unsuitable spare parts or operating materials.
- Page 41 De-commissioning, Storage and Transport Decommissioning, Storage and Transport 12.1 Decommissioning It is necessary to decommission the machine if: it will not be needed for a short time, it is to be moved to another location, it is no longer needed, it is to be scrapped.
- Page 42 De-commissioning, Storage and Transport 12.4 Transportation Pre–condition: The machine must stand completely on a pallet or wooden base. Machine damage from incorrect transport. CAUTION Do not lift by the compressed air inlet or outlet. Do not lay the machine on its side. Transport only by fork truck operated only by personnel trained and authorized in the safe use of the transport equipment.
- Page 43 Annex Annex 13.1 Diagrams and Drawings 13.1.1 Pipeline and instrument flow diagram (P&I diagrams) 13 --- 36...
- Page 46 Appendix 13.1.2 Dimensional Drawing 13 --- 39...
- Page 48 Appendix 13.1.3 Electrical diagram 13 --- 41...
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